Impact mitigation fit pods

ABSTRACT

The protective helmet, the fit pod assemblies and the respective components relates to methods, devices, and systems for improved helmet systems to enhance athletic performance by dispersing impact forces and/or improving helmet comfort and/or fit through size customization and/or conforming to contours of a wearer&#39;s head. If desired, the various fit pod assemblies can include modular features to provide a semi-custom and/or customized feel for plug and play assembly and/or retrofitting a commercially available helmet and/or other item of protective clothing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority to, U.S.patent application Ser. No. 17/113,407, entitled “Impact Mitigation FitPods,” filed Dec. 7, 2020, which is a continuation of Patent CooperationTreaty Application Serial No. PCT/US2019/036092, entitled “ImpactMitigation Fit Pods,” filed Jun. 7, 2019, which claims benefit of U.S.Provisional Patent Appl. Ser. No. 62/682,102 entitled “Impact MitigationPods,” filed Jun. 7, 2018, U.S. Provisional Patent Appl. Ser. No.62/748,309 entitled “Impact Mitigation Pods,” filed Oct. 19, 2018, andU.S. Provisional Patent Appl. Ser. No. 62/810,211 entitled “ImpactMitigation Pods,” filed Feb. 25, 2019, which all the disclosures areincorporated by reference herein in its entireties.

TECHNICAL FIELD

The present invention relates to methods, devices, and systems forimproved helmet systems with fit pods and/or improved comfort liners toenhance athletic performance by reducing acceleration, dispersing impactforces and/or improving helmet comfort and/or fit. If desired, thevarious improved helmet comfort liner components can include modularcomponents as well as semi-custom and/or customized components for plugand play assembly and/or retrofitting a commercially available helmetand/or other item of protective clothing.

BACKGROUND OF THE INVENTION

Helmets and other protective apparel typically incorporate impactabsorbing structures to desirably prevent and/or reduce the effect ofcollisions between the wearer and other stationary and/or movingobjects. For example, an athletic helmet typically protects a skull andvarious other anatomical regions of the wearer from collisions with theground, equipment, other players and/or other stationary and/or movingobjects, while body pads and/or other protective clothing seeks toprotect other anatomical regions. Helmets are typically designed withthe primary goal of preventing traumatic skull fractures and other blunttrauma, while body pads and ballistic armors are primarily designed tocushion blows to other anatomical regions and/or prevent/resist bodypenetration by high velocity objects such as bullets and/or shellfragments.

However, the proper functioning of a helmet, its impact structuresand/or comfort liners is often highly dependent upon the proper sizingand “fit” of the headgear to the wearer's head. A helmet that does notfit and/or is uncomfortable to wear is often not worn, resulting in theabsence of the helmet when it is needed for protection. Current helmetmanufacturers often provide sub-optimal methods for sizing and/orfitting of a helmet because current fitting/sizing methods are generallyineffective in accommodating the unique shape and size of every wearer'shead, resulting in an inaccurate sizing and/or shaping of the helmetand/or impact structures for the wearer. Inaccurate sizing or shaping ofthe helmet supports can allow undesirable movement between the wearer'shead and the helmet structures, as well as increased pressure of thehelmet on regions of the wearer's head (i.e., “hot spots”), and suchhelmets may not effectively protect the wearer's head from trauma andthe effects of intense physical contact and may perform improperly toabsorb and/or significantly ameliorate impacts. For example, a helmetthat is too large for a wearer's head can allow the user's head to movewithin the helmet, allowing the user's head to contact sides of thehelmet in an undesirable manner during impact. Another majorconsideration in protective headgear is wearer comfort—if the helmet isuncomfortable or painful to wear, this discomfort may distract theuser's attention (potentially leading to more severe impacts) and/or maycause the user to remove or displace the helmet prior to the moment ofimpact. In a similar manner, a helmet that is too small for the wearer'shead may be uncomfortable or painful for the wearer to wear.

Furthermore, the use of outdated impact mitigation technologies and/orcomfort liners may, in certain instances, greatly reduce theeffectiveness of the helmet system and potentially lead to increasedincidence and/or severity of injuries. Many conventional footballhelmets are manufactured with inflatable comfort liners that may besometimes combined with soft foam comfort liners and/or other materialsin an effort to help attenuate impact forces incident to the helmet.These inflatable liners can have a plurality of separate inflatablecells, with these cells adjacently arranged into a general shape insidethe helmet, often with interconnect air passageways and the inflatablecells often include a separate valve-controlled inflation tube that mayextend out the back or side of the helmet. To “fit” the helmet, thewearer or an assistant (often referred to as the “sizer”) may increaseor decrease the pressure of air or other fluid/gas within the inflatablecomfort liner to desirably increase and/or decrease the size of thecells, while seeking to improve the wearer's fit, comfort andprotection. Unfortunately, inflatable liners and related technologyoften function sub-optimally, in that the inflatable cells are prone toleakage, damage and are highly sensitive to environmental temperatures(i.e., they commonly increase or decrease in size due to temperaturefluctuations and/or air pressure changes). Inflatable cells also requiremore frequent of adjustment (or “spot checks”) in comparison to foamsand/or other materials to maintain proper sizing in-betweenpressurization and/or depressurization cycles. In addition, inflatablecells often suffer from a lack of uniform inflation, where some portionsof the inflatable comfort liner may be over-inflated and other portionsunder-inflated; and the distribution of inflatable cells may not beuniform and/or may cause a tilting effect (i.e., inflatable jaw pads orside pads) or a “lift effect” (with an inflatable crown pad) on thehelmet. Such negative characteristics of the inflatable comfort linerscan adversely affect the fit of the helmet and reduce or eliminate anyprotection the helmet presumes to provide.

In addition, research has been revealing that traumatic brain injuries(TBI's) are not only caused by linear impacts, but impacts resultingfrom oblique, tangential and/or rotational acceleration because thebrain is sensitive to rotational motion. Rotational motion and/oracceleration may cause TBI's that results from interrupting the speed ofthe body relative to the head, which the unrestricted movement of thehead occurs out of synchrony with the movement of the neck, torso,and/or lower limbs of the body. Injuries received by players, such asconcussions, subdural hemorrhage, hematomas and diffuse axonal injury,can be more easily caused by rotational head motion. Unfortunately,current helmet designs to not adequately protect the head from TBI's dueto oblique, tangential and/or rotational acceleration.

BRIEF SUMMARY OF THE INVENTION

Therefore, there is a need for an improved protective helmet system andmethods for sizing and fitting helmets and other protective apparel fora wearer. Improved methods of sizing and shaping a helmet may desirablytake into account the shape, size and/or anatomical variability of thewearer's skull. Furthermore, an improved helmet system may include amodular fit pod system to improve and/or enhance helmet shape, size,comfort, fit and/or attenuation in response to high intensity and/orrepetitive impact events. This is achieved by providing a differentsizes and thicknesses of each fit pod assembly and iterating to acquirethe best fit and impact protection.

In one exemplary embodiment, the modular fit pod system may comprise oneor more fit pod assemblies. The fit pod assemblies comprise a fit podand a connection mechanism, the fit pod comprises a top layer, a bottomlayer, a first foam layer and a second foam layer; the first foam layerand the second foam layer disposed between the top layer and bottomlayer, the top layer having top surface and a bottom surface, the toplayer top surface having a plurality of channels that extend from thetop surface towards the bottom surface, the bottom layer having at leastone opening, the at least one opening sized and configured to receive aportion of a second portion of the connection mechanism, the top layercoupled to bottom layer; and the connection mechanism having a firstportion and the second portion, the first portion having a planarconfiguration, the second portion extending perpendicularly away fromthe first portion, the second portion sized and configured to bepositioned within the at least one opening. The fit pod assemblies maycomprise a flat, planar configuration and/or a curved configuration. Thetop layer and/or bottom layer may comprise the same materials ordifferent materials. The first foam layer and the second foam layer maycomprise the same foam materials or different foam materials.

In another exemplary embodiment, the modular fit pod system may comprisean alternate one or more fit pod assemblies. The alternate one or morefit pod assemblies comprise a fit pod and a connection mechanism, thefit pod having top surface and a bottom surface, the fit pod top surfacehaving a plurality of channels that extend from the top surface towardsthe bottom surface. The connection mechanism having a first portion andthe second portion, the first portion being larger than the secondportion, the second portion extending perpendicularly away from thefirst portion, the connection mechanism being coupled to the fit pod.More specifically, the connection mechanism first portion is coupled tothe fit pod bottom surface. The fit pod may comprise a foam material.The fit pod assemblies may comprise a flat, planar configuration and/ora curved configuration.

In another exemplary embodiment, the modular fit pod system may comprisean alternate one or more fit pod assemblies. The alternate one or morefit pod assemblies comprise a fit pod, a connection mechanism, and anelastomeric support system. The fit pod having top surface and a bottomsurface, the fit pod top surface having a plurality of channels thatextend from the top surface towards the bottom surface. The fit podassemblies may comprise a flat, planar configuration and/or a curvedconfiguration. The one or more fit pods further comprise one or morefoam layers that are disposed within the fit pod. The elastomericsupport system may comprise an elastomeric polymer frame, a wovenelastomeric fabric or cover, an elastomeric fabric or cover (such as a2-way or 4-way stretch fabric), and/or one or more springs. Theelastomeric support system may further comprise a low friction materialor layer, the low friction material or layer coupled the fit pod bottomsurface. The low friction material or layer to allow the connectionmechanism to be slidably movable from a first position, the firstposition being the connection mechanism is positioned in a neutralposition, to a second position, which the connection mechanism ispositioned laterally from the neutral position after an oblique ortangential impact force. The elastomeric support system may be coupledto the one or more fit pods. The connection mechanism having a firstportion and the second portion, the first portion being larger than thesecond portion, the second portion extending perpendicularly away fromthe first portion, the connection mechanism being coupled to the fitpod. More specifically, the connection mechanism first portion iscoupled to the fit pod bottom surface and/or coupled to the low-frictionmaterial or layer. The fit pod may comprise a foam material.

In one exemplary embodiment, an improved protective helmet system maycomprise a helmet and one or more modular fit pods and/or fit podlayer(s). The helmet may include an outer layer. The helmet may furthercomprise an inner layer and an impact mitigation structure and/or layer,the impact mitigation layer and/or structure disposed between the innerand outer layer, and/or any combination thereof. The fit pod assembliesare disposed within the helmet and may be desirably positioned aroundvarious locations or regions around the wearer's head, such as coveringmuch of the area between an inner shell of the helmet and the user'shead. The fit pod layer comprises a plurality of fit pod assemblies. Theplurality of fit pod assemblies may comprise a flat, planarconfiguration and/or a curved configuration. Such plurality of fit podassemblies may include one or more of the following: a frontal assembly(or front), a crown assembly, an occipital assembly (or lower-back), amid-back assembly, a parietal assembly (or midline), and a temporalassembly (right and/or left sides), and/or any combination(s) thereof.At least a portion of the fit pod assemblies may be removably coupled tothe helmet, including at least one inner layer, impact mitigation layer,outer layer and/or any combination thereof to facilitate energyabsorption, reduce angular motion of the wearer after impact, enhancefit and comfort.

In one exemplary embodiment, the improved protective helmet system maycomprise a helmet, one or more fit pod assemblies and/or a fit podlayer, and a comfort liner. The helmet having at least one outer layer,an optional inner layer and an impact mitigation layer disposed betweenthe inner and outer layer, and/or any combination thereof. The fit podlayer comprises a plurality of fit pod assemblies. The fit pod layer mayinclude impact mitigation structure or material, comfort foam and may bedesirably positioned around various locations of the wearer's head, suchas covering some of the area between an inner shell of the helmet andthe user's head. The fit pod assemblies may also include a connectionmechanism to connect or attach the pods to the inner shell, the impactmitigation layer, the outer shell or any other parts of the helmetsystem. Such plurality of fit pod assemblies may include one or more ofthe following: a frontal assembly (or front), a crown assembly, anoccipital assembly (or lower-back), a mid-back assembly, a parietalassembly (or midline), and a temporal assembly (right and/or leftsides), and/or any combination(s) thereof. At least a portion of the fitpod assemblies may be removably coupled to at least one inner layer,impact mitigation layer, outer layer, comfort liner and/or anycombination thereof to facilitate energy absorption, reduce angularmotion of the wearer after impact, enhance fit and comfort. The comfortliner may comprise a first layer, a second layer, and a foam layer. Thefoam layer may include a plurality of segmented foam pads, each of theplurality of segmented foam pads optionally being separated by gap. Thefoam layer can be disposed between the first and second layer, or thefoam layer could be laminated with first and/or second layers. The gaphas a thickness, the thickness allowing substantial flexibility and/or apivotal connection.

In one exemplary embodiment, an improved helmet system may comprise ahelmet and one or more fit pod assemblies or fit pod layers. The one ormore fit pod layers may comprise at least one bottom layer, at least onetop layer, at least one foam layer, a connection mechanism, and/or anycombination thereof. The at least one bottom layer or least one toplayer may comprise a plastic material, a foam material or foam layer, aresilient fabric that may be a two-way or four-way stretch materialand/or any elastic material, and/or any combination thereof. In oneembodiment, the top layer and/or bottom layer may comprise a 2-way or 4way stretch fabric and a polymer film. The polymer films comprise apolyethylene film, polypropylene film, a polyurethane film, a nylonfilm, a polyester film, a polyvinyl chloride film and/or any combinationthereof. The polymer film may be coupled or laminated to the 2-way or4-way stretch fabric. The at least one top layer and at least one bottomlayer may be the same material, or they may be different materials. Theat least one foam layer may a one single layer, and/or it may be aplurality of foam layers (two or more). In addition, the pocketed fitpod assemblies may further comprise an impact mitigation layer.

In one exemplary embodiment, an improved helmet system may comprise ahelmet and one or more modular fit pods and/or fit pod layer(s) to helpprotect against oblique, tangential and/or rotational acceleration. Thehelmet may include an outer layer. The helmet may further comprise aninner layer and/or an impact mitigation layer disposed on an innersurface of the outer layer, and/or between the outer layer or innerlayer, and/or any combination thereof. The fit pod layer may comprise aone or more modular fit pod assemblies. The one or more modular fit podassemblies may be desirably positioned around various locations of thewearer's head, such as covering much of the area between an inner shellof the helmet and the user's head. Each of the fit pod assemblies mayalso include a fit pod, a connection mechanism and an elastomericsupport mechanism. The each one or more fit pods may comprise a toplayer, one or more foam layers, and a bottom layer. The elastomericsupport mechanism may comprise an elastomeric polymer frame, a wovenelastomeric fabric or cover, an elastomeric fabric or cover (such as a2-way or 4-way stretch fabric), and/or one or more springs. Theelastomeric support mechanism may further comprise a low frictionmaterial to allow the connection mechanism to be slidably movable from afirst position, which the connection mechanism is positioned in aneutral position, to a second position, which the connection mechanismis positioned laterally from the neutral position after a tangentialand/or oblique impact force. The elastomeric support system may becoupled to the each one or more fit pods. Such plurality of fit podassemblies may include one or more of the following: a frontal assembly(or front), a crown assembly, an occipital assembly (or lower-back), amid-back assembly, a parietal assembly (or midline), and a temporalassembly (right and/or left sides), and/or any combination(s) thereof.At least a portion of the fit pod assemblies may be removably coupled toat least one inner layer, impact mitigation layer, outer layer and/orany combination thereof to facilitate energy absorption, reduce angularmotion and/or rotational motion of the wearer after impact, enhance fitand comfort.

In one exemplary embodiment, the improved helmet system may comprise ahelmet, one or more modular jaw pod system. The jaw fit pod system cancomprise a jaw fit pod assembly and a bridge fit pod assembly. The jawpod assembly comprises a jaw connection plate, a face frame or base, andat least one jaw fit pod. The face frame have a first surface and asecond surface, the first or second surface has a cavity, the cavity isshaped and configured to receive the jaw connection plate, the jawconnection plate shaped and configured to fit within the cavity, the atleast one jaw fit pod and/or jaw fit pod assembly having at least onefoam layer, the jaw fit pod and/or jaw fit pod assembly coupled to thefirst or second surface of the face frame. The bridge fit pod assemblycomprises a bridge connection plate, a bridge frame or base, and abridge fit pod. The bridge frame have a first surface and a secondsurface, the first or second surface has a cavity, the cavity is shapedand configured to receive the bridge connection plate, the bridgeconnection plate shaped and configured to fit within the cavity, thebridge fit pod and/or bridge fit pod assembly having at least one foamlayer, the bridge fit pod and/or jaw fit pod assembly coupled to thefirst or second surface of the bridge frame. The bridge fit pod and/orthe bridge fit pod assembly being removably coupled to the helmet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 depicts one embodiment of an improved helmet system;

FIG. 2 depicts an alternate embodiment of an improved helmet system;

FIGS. 3A-3B depicts various views of one embodiment of an improvedhelmet outer layer;

FIGS. 4A-4B depicts various views of an alternate embodiment of animproved helmet outer layer;

FIGS. 5A-5D depicts cross-sectional view of one embodiment of animproved protective helmet system;

FIGS. 6A-6C depict various views of one embodiment of a helmet innerlayer;

FIGS. 7A-7B depict one embodiment of a fit pod or fit pod assembly andits cross-sectional view;

FIGS. 8A-8C depict various views of one embodiment of a fit podassembly;

FIGS. 9A-9H depict various views of one embodiment of a fit pod;

FIGS. 10A-10C depict various views of one embodiment of snap postconnection mechanism;

FIGS. 11A-11H depict various views of one embodiment of a fit podassembly;

FIGS. 12A-12B depict a front view and a cross-sectional view of oneembodiment of a fit pod assembly;

FIG. 12C depicts an exploded view of one embodiment of a fit podassembly;

FIGS. 13A-13H depict various views of one embodiment of a top layer of afit pod;

FIGS. 14A-14H depict various views of an alternate embodiment of snappost connection mechanism;

FIGS. 15A-15H depict various views of an alternate embodiment of a fitpod assembly;

FIGS. 16A-16D depict various views of an alternate embodiment of a fitpod assembly;

FIGS. 16E-16F depict various views of one embodiment of a fit podassembly;

FIG. 16G depicts an isometric view of alternate embodiments of a fitpod;

FIGS. 17A-17H depict various views an alternate embodiment of a fit podassembly;

FIG. 18A-18F depicts various views of one embodiment of a rotational fitpod assembly;

FIG. 19A-19C depicts the cross-section views of fit pod assembly priorto impact and after impact of FIGS. 18A-18F;

FIGS. 20A-20B depict various views of one embodiment of a helmet withfit pods or fit pod assemblies;

FIGS. 21A-21B depicts a front view of one embodiment of an improvedcomfort liner;

FIG. 21C depicts a cross-sectional view of a portion of a comfort linerof FIGS. 21A-21B;

FIGS. 22A-22B depicts a side and front view of an alternate embodimentof an improved comfort liner;

FIG. 23 depicts a front view of an alternate embodiment of an improvedcomfort liner;

FIGS. 24A-24D depicts various views of one embodiment of a helmet withan improved comfort liner;

FIGS. 25A-25B depicts a front view and exploded view of an alternateembodiment of a comfort liner;

FIGS. 26A-26F depicts various views of a frontal fit pod assembly;

FIGS. 27A-27B depicts front view and a magnified view of one embodimentof fit pod jaw assembly;

FIG. 27C depicts an exploded view of a fit pod jaw assembly of FIGS.27A-27B;

FIGS. 28A-28E depict various views of an alternate embodiment of a fitpod jaw assembly; and

FIG. 28F depicts a side view of a helmet with a fit pod jaw assembly ofFIGS. 28A-28E.

DETAILED DESCRIPTION OF THE INVENTION

The fit pod assemblies and the improved protective helmet system willenhance and/or optimize a player's fit and/or impact protection. The fitpod assemblies may be desirably available in different thicknesses,different shapes and configurations, different foam layers, so they maybe easily adapted and/or tailored to a specific wearer's sport, positionand/or occupation. The one or more modular fit pod assemblies areremovably connected to an interior surface of a helmet and may bepositioned around various locations of the wearer's head. Such pluralityof fit pod assemblies may include one or more of the followinglocations: a frontal assembly (or front), a crown assembly, an occipitalassembly (or lower-back), a mid-back assembly, a parietal assembly (ormidline), and a temporal assembly (right and/or left sides), and/or anycombination(s) thereof. At least a portion of the fit pod assemblies maybe removably coupled to at least one inner layer, impact mitigationlayer, outer layer and/or any combination thereof to facilitate energyabsorption, reduce angular motion and/or rotational motion of the wearerafter impact, enhance fit and comfort. Since the fit pod assemblies canbe tailored to the particular demands of each wearer, the fit podassemblies may be retrofitted to a commercially available helmet; and/or(2) incorporated into a new, customized helmet system withwearer-specific attributes.

Furthermore, the one or more fit pod assemblies have a uniqueconstruction that further enhances flexibility of the fit pod and/or fitpod assembly to conform to the natural shape or contours of the wearer'shead. The one or more fit pod and/or fit pod assemblies comprise aplurality of channels or grooves disposed on a top layer and haveflexible and/or stretchable materials for the top and bottom layers thatallows the one or more fit pods and fit pod assemblies to easily deformfrom a flattened configuration to a curved configuration. The pluralityof channels or grooves have a channel width, and the channel widthchanges from a first position to a second position. The first positionbeing a neutral uncoupled position, and the second position having atleast one of the plurality of channels with a decreased channel widthafter being removably coupled to the helmet.

The various fit pod assemblies and/or protective helmet components anddesigns provided herein are depicted with respect to American football,but it should be understood that the various devices, methods and/orcomponents may be suitable for use in protecting players in variousother athletic sports, as well as other occupations that requireprotection, such as law enforcement, military, construction and/orinformal training session uses. For example, the embodiments of thepresent invention may be suitable for use by individuals engaged inathletic activities such as baseball, bowling, boxing, cricket, cycling,motorcycling, golf, hockey, lacrosse, soccer, rowing, rugby, running,skating, skateboarding, skiing, snowboarding, surfing, swimming, tabletennis, tennis, or volleyball, or during training sessions relatedthereto.

Full Helmet Systems

FIG. 1 depicts an exploded view of one embodiment of an improvedprotective helmet system 100. In one exemplary embodiment, an improvedprotective helmet system 100 may comprise a helmet and a modular fit podlayer 102. The helmet having at least one outer layer 106, an innerlayer 104, supplemental frontal fit pod 108, an impact mitigation layer(not shown) disposed between the inner 104 and outer layer 108, and/orany combination thereof. The fit pod layer 102 may include a pluralityof fit pod assemblies that are desirably positioned around the surfaceof the wearer's head in different regions. Such plurality of fit podassemblies may include regions such as one or more of the following: afrontal assembly (or front), a crown assembly, an occipital assembly (orlower-back), a mid-back assembly, a parietal assembly (or midline), anda temporal assembly (right and/or left sides), jaw assembly (i.e., rightand left sides) and/or any combination(s) thereof. At least a portion ofthe fit pod assemblies may be removably coupled to at least one innerlayer, impact mitigation layer, outer layer, comfort liner and/or anycombination thereof to facilitate energy absorption, reduce angularmotion of the wearer after impact, enhance fit and comfort. Theplurality of fit pod assemblies may include the fit pod and a connectionmechanism. At least a portion of the fit pod assemblies may be removablycoupled to at least one inner layer, impact mitigation layer, outerlayer, comfort liner and/or any combination thereof to facilitate energyabsorption, reduce angular motion of the wearer after impact, enhancefit and comfort.

FIG. 2 depicts an exploded view of an alternate embodiment of animproved protective helmet system 200. In one exemplary embodiment, theimproved protective helmet system 200 may comprise a helmet, a fit podlayer 202, and a comfort liner 210. The helmet having at least one outerlayer 206, an inner layer 204 and an impact mitigation layer (not shown)disposed between the inner 204 and outer layer 206, a supplemental fitpod 208, and/or any combination thereof. The fit pod layer 202 mayinclude a plurality of fit pod assemblies that are desirably positionedaround the circumference of the wearer's head in different regions. Suchplurality of fit pod assemblies may include regions such as at least onefrontal assembly (or front), a crown assembly, an occipital assembly (orlower-back), a mid-back assembly (i.e., right and/or left sides), aparietal assembly (or midline), and a temporal assembly (right and/orleft sides), jaw assembly (i.e., right and left sides) and/or anycombination(s) thereof. The comfort liner 210 may comprise a firstlayer, a second layer, and a foam layer, while in at least onealternative embodiment the comfort liner may be formed from thermoformedfoam (optionally without one or both of the inner and outer layers). Thefoam layer may include a plurality of segmented foam pads, each of theplurality of segmented foam pads are separated by gap. The foam layer isdisposed between the first and second layer. The gap has a thickness,the thickness allowing substantial flexibility and/or a pivotalconnection. Each of the plurality of fit pod assemblies may include thefit pod and a connection mechanism. At least a portion of the fit podassemblies may be removably coupled to at least one inner layer, impactmitigation layer, outer layer, comfort liner and/or any combinationthereof to facilitate energy absorption, reduce angular motion of thewearer after impact, enhance fit and comfort

Helmet

The helmet having at least one outer layer, an inner layer and an impactmitigation layer (not shown) disposed between the inner and outer layer,a supplemental frontal fit pod, and/or any combination thereof. Theprotective helmet may further comprise a chinstrap (not shown), afaceguard (not shown) and/or a visor (not shown).

FIGS. 3A-3B and 4A-4B depict isometric views of different embodiments ofan outer layer. The outer shell or outer layer 300,400 may bemanufactured from a relatively rigid material or rigid material, such aspolyethylene, nylon, polycarbonate materials, acrylonitrile ButadieneStyrene (ABS), polyester resin with fiberglass, thermosetting plastics,and/or any other rigid thermoplastic materials. Alternately, the outershell 1060 may be manufactured from a relatively deformable material,such as polyurethane and/or high-density polyethylene, where suchmaterial allows some flexibility and/or local deformation of the outerlayer 502 and/or the impact mitigation layer 504 upon impact 508, butprovide enough rigidity to prevent the breakage or damage to the helmetas shown in FIG. 5C-5D.

FIGS. 5A-5D depict cross-sectional views of one embodiment of aprotective helmet 500 showing the outer layer 502, the impact mitigationlayer 504 and the inner shell 506. The impact mitigation layer 504 maycomprise one or more impact mitigation structures. The impact mitigationstructures may comprise at least a portion of filaments, at least aportion of laterally supported filament (LSF) structures, at least aportion of auxetic structures, at least a portion of undulatedstructures, and/or any combination thereof. impact mitigation layers maycomprise a portion of at least one of: filaments, laterally supportedfilaments, auxetic structures, impact foam or foam layer, TPU cones,inflatable bladders, shock bonnets, and/or any combination thereof.

In one embodiment, the impact mitigating structures and/or impactmitigation layers can comprise at least a portion of filaments. The atleast a portion of filaments may be thin, longitudinally extendingmembers having a 3:1 to 1,000:1 aspect ratio (having its length beinggreater than its width or diameter). The at least a portion of filamentsmay be shaped and configured to deform non-linearly in response to animpact force. The non-linear deformation behavior is expected to provideimproved protection against high-impact forces, and/or oblique forces.The non-linear deformation behavior is described by at least a portionof the filaments stress-strain profile. The non-linear stress-strainprofile illustrates that there can be an initial rapid increase in force(region I) followed by a change in slope that may be flat, decreasing orincreasing slope (region II), followed by a third region with adifferent slope (region Ill).

In another embodiment, the at least a portion of the filaments maycomprise filaments that buckle in response to an incident force, wherebuckling may be characterized by a localized, sudden failure of thefilament structure subjected to high compressive stress, where theactual compressive stress at the point of failure is less than theultimate compressive stress that the material is capable ofwithstanding. Furthermore, the at least a portion of the filaments maybe configured to deform elastically, allowing the at least a portion ofthe filaments to substantially return to their initial configurationonce the external force is removed.

In another embodiment, the impact mitigating structures and/or impactmitigation layers can comprise at least a portion of a plurality offilaments that are interconnected by laterally positioned walls orsheets or other supplemental filaments in a polygonal configuration,otherwise known as laterally supported filaments (LSF). The at least aportion of the LSF structures, where the filaments are arranged in ahexagonal pattern interconnected by laterally positioned walls or othersupplemental filaments. Alternatively, other polygonal structures knownin the art may be contemplated, such as triangular, square, pentagonal,hexagonal, septagonal, octagonal, and/or any combination thereof. Aplurality of sheets or lateral walls can be secured between adjacentpairs of filaments with each filament having a pair of lateral wallsattached thereto. In the disclosed embodiment, the lateral walls can beoriented approximately 120 degrees apart about the filament axis(preferably, it may be 90 to 135 degrees apart about the filament axis),with each lateral wall extending substantially along the longitudinallength of the filament. In addition, each of the lateral walls may beoriented differently, and have symmetric orientation or asymmetricorientation. The shape, wall thickness or diameter, height, andconfiguration of the lateral walls, supplemental filaments and/orfilaments may vary to “tune” or “tailor” the structures to a desiredperformance. For example, one embodiment of a hexagonal structure mayhave a tapered configuration. The hexagonal structure can have a topsurface and a bottom surface, with the bottom surface perimeter (and/orbottom surface thickness/diameter of the individual elements) that maybe larger than the corresponding top surface perimeter (and/orindividual element thickness/diameter). In another example, thehexagonal structure can have an upper ridge. The upper ridge can alsofacilitate connection to another structure, such as an inner surface ofa helmet, an item of protective clothing, and/or a mechanical connection(e.g., a grommet or plug having an enlarged tip that is desirablyslightly larger than the opening in the upper ridge of the hexagonalelement).

Furthermore, the polygonal or hexagonal structures may be manufacturedas individual structures or in a patterned array. The individualstructures can be manufactured using an extrusion, investment casting orinjection molding process. Each individual polygonal or hexagonalstructure may be affixed directly to a base in a custom location orpattern that may be arranged in continuous or segmented array. Also,they may have the same shape and configuration with repeatingsymmetrical arrangement or asymmetrical arrangement and/or differentshape and configurations with repeating symmetrical arrangement orasymmetrical arrangement.

Conversely, the polygonal or hexagonal structures may be manufactureddirectly into a patterned array that is affixed to at least one basemembrane. The base membrane may be manufactured with a polymeric or foammaterial. The polymeric or foam material may be flexible and/or elasticto allows it to be easily bent, twisted or flexed to conform to complexsurfaces. Alternatively, the polymeric and/or foam material may besubstantially rigid. The manufacturing of each patterned array ofpolygonal or hexagonal structures may include extrusion, investmentcasting or injection molding process. The base membrane with thepolygonal or hexagonal structures may be affixed directly to at least aportion of the base or the entirety. Affixing each pattered array ofpolygonal or hexagonal structures may be arranged in continuous orsegmented arrays. Also, the polygonal or hexagonal structures may havethe same shape and configuration with repeating symmetrical arrangementor asymmetrical arrangement and/or different shape and configurationswith repeating symmetrical arrangement or asymmetrical arrangement.

In another embodiment, the impact mitigation structure may comprise atleast a portion of auxetic structures. The auxetic structures mayinclude a plurality of interconnected members forming an array ofreentrant shapes positioned on the flexible head layer. Such auxeticstructures may be coupled or affixed to the protective enclosure base asa continuous layer or in segmented arrays. The term “auxetic” generallyrefers to a material or structure that has a negative Poisson ratio,when stretched, auxetic materials or structures become thicker (asopposed to thinner) in a direction perpendicular to the applied force.Such auxetic structures can result in high energy absorption and/orfracture resistance. In particular, when a force is applied to theauxetic material or structure, the impact can cause it to expand (orcontract) in one direction, resulting in associated expansion (orcontraction) in a perpendicular direction. It should be recognized thatthose skilled in the art could utilize auxetic structures to includedifferently shaped segments or other structural members and differentshaped voids.

In another embodiment, the impact mitigation structures may compriseundulated structures. The undulated structures may comprise chevronpattern, herringbone pattern, and/or zig zag pattern. Such undulatedstructures allow large elastic deformations by releasing strain—astructural deformation, then returning to its original configurationafter the impact is removed.

The inner shell or inner layer 506 may be manufactured from a relativelyrigid or rigid material. The inner shell or inner layer 506 being nestedwithin the impact mitigation layer 504. The inner shell 506 having anexterior surface and an interior surface, the at least a portion of theexterior surface of the inner shell 506 may contact an exterior surfaceof the impact mitigation layer 504. The at least one inner shell 506being a continuous shell and/or a two-piece shell that conforms andsurrounds the head of the wearer. Accordingly, the at least one innershell 506 may be a rigid material. The at least one inner shell 506 maybe more rigid than the outer shell 502 and/or more rigid than the impactmitigation layer 504. In some embodiments, the inner shell 506 is fiveto 100 times stiffer or more rigid than the outer shell 502 and/or theimpact mitigation layer 504. The rigid material may comprisepolycarbonate (PC). Alternatively, the inner shell 506 comprises arelatively rigid material or relatively stiff material. The relativelyrigid material may be stiff or rigid enough to withstand breakage orcracking, but flexible enough to deform slightly and distribute incidentforces after an impact. The at least one inner shell 506 may comprise athermoplastic material. Thermoplastic materials may comprisepolyurethane, polycarbonate, polypropylene, polyether block amide,and/or any combinations thereof. Alternatively, the inner shell 506 maycomprise a deformable material, such as polyurethane and/or high-densitypolyethylene, where such material allows some flexibility and/or localdeformation upon impact, but provide enough rigidity to prevent thebreakage or damage to the helmet.

FIGS. 6A-6B depicts various views of an alternate embodiment of an innershell or inner layer 600. The inner shell or inner layer 600substantially surrounds the head of the wearer and conforms to the shapeof the wearer's head. The inner shell may comprise a first plurality ofopenings 602, a second plurality of openings 606, and a plurality ofretention posts 604. The first plurality of openings 602 may be sizedand configured to receive a portion of the fit pod connection mechanism(not shown). Such size and configuration will allow the portion of thefit pod connection mechanism to be compressed, and pushed through thefirst plurality of openings, and once through, the at least a portion ofthe connection mechanism will expand and stay in place. The firstplurality of openings 602 may match or substantially match the shape ofthe fit pod connection mechanism to prevent unintended rotation,misalignment or improper orientation. Furthermore, the connectionmechanism may comprise an alignment feature, a plurality of detentsand/or a detent body that allows for intuitive placement of the fit podassembly in the correct direction to prevent improper placement ororientation. Tactile feedback with a “snap” may be desired. Accordingly,a second plurality of openings may be sized and configured to secureother components of the helmet, such as a portion of the outer layerand/or the impact mitigation layer. The plurality of retention posts 604extend perpendicularly from an external surface of the inner layer 600.Alternatively, the retention posts 605 may extend to an oblique angle,the oblique angle ranging from 5-30 degrees. The retention posts 605 maybe cylindrically shaped and may comprise a threaded hole for screwattachment to the impact mitigation layer and/or the outer layer.

Fit Pod Assemblies

The protective helmet system may comprise a helmet and a modular fit podlayer. The modular fit pod layer may comprise a plurality of fit podassemblies positioned in different regions around the wearer's head. Theplurality of fit pod assemblies may be removably coupled to an innerlayer or inner shell, and/or removably coupled to a base layer. The baselayer may comprise a polymer, the polymer may comprise polycarbonate ora flexible material. Each of the plurality fit pod assemblies comprise afit pod and a connection mechanism. The plurality of fit pod assembliesmay be provided in different thicknesses to accommodate different needsof each wearer. Each of the plurality of fit pod assemblies may bedifferent thicknesses or the same thicknesses.

In various embodiments, a helmet or other item of protective clothing orequipment or garment may incorporate one or more fit pod layers and/orfit pod assemblies. The one or more pod assemblies may include at leastone fit pod (known as “pods” or “modular pods”) and/or a connectingmechanism. The one or more fit pod assemblies can be modular and placedinto any configuration within the helmet. Each of the fit pod assembliesmay include easily removable connections to couple to the helmet orvarious components thereof. Each of the plurality of fit pod assembliesmay be manufactured to accommodate and protect the desired region of thewearer's head. Such plurality of fit pod assemblies may include regionssuch as one or more of the following: a frontal assembly (or front), acrown assembly, an occipital assembly (or lower-back), a mid-backassembly (right and/or left sides), a parietal assembly (or midline),and a temporal assembly (right and/or left sides), jaw assembly and/orany combination(s) thereof.

FIGS. 7A and 7B depict perspective and cross-sectional views of oneexemplary embodiment of a fit pod 700. The fit pod 700 may be generallyshaped as a regular or irregular polygon, the regular polygon maycomprise a triangle, square, rectangle, pentagon, hexagon, septagon,octagon, and/or any combination thereof. The fit pod 700 may compriseone or more channels 702 and one or more vent openings (not shown). Thefit pod 700 may comprise a top surface 716 and a bottom surface 718. Theone or more channels 702 may be disposed onto the top surface 716, theone or more channels 702 may be spaced apart from each other in asymmetric or non-symmetric pattern, and the one or more channels 702 mayextend to the perimeter of fit pod. The one or more channels 702 mayextend from the top surface 716 towards the bottom surface 718. The oneor more channels may have a first and/or second end, which at least thefirst or second end of each of the one or more channels 702 mayintersect at an intersection point 704. The one or more channels maycomprise a width, a depth, and a length. The channel depth and/or widthfacilitates the flexibility of the fit pod 700. For example, a largerdepth can increase the flexibility whether folded inward or outward.Also, a larger width allows increased deflection when folded inwards.Therefore, when the fit pods are coupled to the helmet, the fit pod 700folds inward from a flat configuration to a curved configuration,thereby decreasing or narrowing the channel width. In one embodiment,the channel width may have a first position, the first position being anon-coupled, neutral position, and the second position, the secondposition being a coupled position (e.g., coupled to the helmet), wherethe first position channel width is greater than the second positionchannel width.

The fit pod 700 may comprise at least one bottom layer 708, at least onetop layer 706, and/or at least one foam layer 710, 712. The fit pod 700may further comprise an impact mitigation structure (not shown), The atleast one bottom layer 708 or least one top layer 706 may comprise atleast one foam material or at least one foam layer, a plastic material,a resilient fabric that may be a two-way or four-way stretch materialand/or any elastic material. The plastic material may comprise anacrylic, a polypropylene, a polycarbonate, anacrylonitrile-butadiene-styrene, a polyethylene, a polyethyleneterephthalate, and/or any combination thereof. In one embodiment, thetop layer and/or bottom layer may comprise a 2-way or 4 way stretchfabric and a polymer film. The polymer films comprise a polyethylenefilm, polypropylene film, a polyurethane film, a nylon film, a polyesterfilm, a polyvinyl chloride film and/or any combination thereof. Thepolymer film may be coupled or laminated to the 2-way or 4-way stretchfabric. The at least one top layer 706 and at least one bottom layer 708may be the same material, or they may be different materials. The atleast one bottom layer 708 may extend beyond the perimeter of the fitpod 700 to create a flange 714.

The impact mitigating structures (not shown) and the at least one foamlayer 710, 712 may be disposed between the bottom layer 708 and/or atleast one top layer 706. The impact mitigation structure may be coupledto the at least one foam layer 710,712 and/or the least one bottom layer708. Such coupling may be accomplished by using adhesives, molding, heatand/or ultrasonic welding, sintering or any other method known in theart. Alternatively, the impact mitigating structures may be“free-floating” between the base or bottom layer 708 and the top layer706. Furthermore, impact mitigation structure may be the same materialas the at least one foam layer 710,712. Alternatively, the impactmitigation structure may be a different material as the at least onefoam layer 710,712.

The at least one foam layer 710,712 may comprise a single layer ormultiple layers, which any of the layers may be comprised of varioustypes of foam. The at least one foam layer can include polymeric foams,quantum foam, polyethylene foam, thermoplastic polyurethane foam (foamrubber), XPS foam, polystyrene, phenolic, memory foam (traditional, opencell, or gel), Ariaprene, impact absorbing foam (e.g., VN600), latexrubber foam, convoluted foam (“egg create foam”), Evlon foam, impacthardening foam, 4.0 Custula comfort foam (open cell low density foam),TPU foam and/or any combination thereof. The at least one foam layer mayhave an open-cell structure or closed-cell structure. The at least onefoam layer can be further tailored to obtain specific characteristics,such as anti-static, breathable, conductive, hydrophilic, high-tensile,high-tear, controlled elongation, and/or any combination thereof. Thefoam layer 710, 712 and/or the impact mitigation structure may have athickness ranging from 7 mm to 25 mm.

The at least one bottom layer 110 and/or the at least one top layer 100can surround the complete perimeter of the impact mitigating structure130 and/or the at least one foam layer 120, completely enclosing theimpact mitigation structure. Alternatively, the at least one bottomlayer 110 and/or the at least one top layer 100 can surround thecomplete perimeter of the impact mitigating structure 130 and/or the atleast one foam layer 120, completely enclosing the impact mitigationstructure leaving a flange around the perimeter.

FIGS. 8A and 8C depict various views of one exemplary embodiment of afit pod assembly 800. The fit pod assembly 800 may comprise a fit pod802 and a connection mechanism 806. The fit pod 802 may be generallyshaped as a regular or irregular polygon, the regular polygon maycomprise a triangle, square, rectangle, pentagon, hexagon, septagon,octagon, and/or any combination thereof. The fit pod 802 may comprise aplurality of channels or grooves 806, and a plurality of vent openings804. The fit pod 802 may comprise a top surface 808 and a bottom surface810. The one or more channels 806 may be disposed onto the top surface808, the one or more channels 806 may be spaced apart from each other ina symmetric or non-symmetric pattern, and the one or more channels 806may extend to the perimeter of fit pod 802. The one or more channels 806may extend from the top surface 808 towards the bottom surface 810. Theplurality of vent openings 804 may extend through the top surface 808 tothe bottom surface to facilitate the movement of air within theprotective helmet for ventilation purposes. The plurality of ventopenings 804 may be circular, oval or elongated. The plurality of ventopenings 804 may be disposed within the plurality of channels or grooves806. The connection mechanism 806 may be coupled to the bottom surface810 of the fit pod 800. The connection mechanism 806 may be positionedcentered between the plurality of channels or grooves 806, and/orpositioned adjacent to the plurality of channels or grooves 806. The fitpod 802 may comprise a flattened or planar configuration, and/or acurved configuration.

FIGS. 9A-9H depicts various views of one embodiment of a fit pod 900.The modular fit pod 900 comprises a top surface 902 and a bottom surface910. The top surface 902 may an include one or more score lines orgrooves or channels 906, which can desirably facilitate flexing of thefit pod 900 when installed into the helmet (not shown). The grooves orchannels 906 may be different widths to increase or decreaseflexibility. The grooves or channels 906 may extend from the top surface902 towards the bottom surface 910. The top surface 902 may comprisebevel edges 904 on the one or more channels 906 and/or the top surfaceperimeter reduce interference when flexing. The grooves or channels 906further extend longitudinally or parallel to the top surface 902. Thegrooves or channels 906 may be spaced apart from each othersymmetrically or asymmetrically. Moreover, the one or more grooves orchannels 906 may have a first end 914 and a second end 916, which eachof the one or more grooves or channels 906 second end 916 may intersectat an intersection point 918. Furthermore, the grooves or channels 906may be spaced apart symmetrically with a desired interior angle 912, andsuch grooves or channels 906 creates a top surface 902 with a first,second and third portions.

In another embodiment, the modular fit pod 900 may include a firstsurface 902, and a second surface 910, while in other embodiments themodular pod 900 may comprise a thermo-foamed foam layer (optionallywithout first 902 and/or second surfaces 910). The first surface 902having a plurality of grooves 906 disposed within, the plurality ofgrooves 906 may extend from the first surface 902 to at least a portiontowards a second surface 910. Desirably, the fit pod 900 can bemanufactured in a flattened configuration, and then the fit pod 900 canbe curved to varying degrees during installation and/or coupling to thehelmet, transforming into a curved configuration (when it desirablyconforms to the inner curvature of the helmet liner). The fit pod 900may further include one or more openings or pores 908 which canfacilitate venting and/or cooling of the wearer's head. In oneembodiment, the modular fit pod 900 may include a first surface 902 anda second surface 910. The first surface 902 having a plurality ofgrooves 906 disposed within, the plurality of grooves 906 may extendfrom the first surface 902 to at least a portion towards the secondsurface 910, the modular fit pod may further include one or moreopenings 908, the one or more openings 908 may be disposed within theplurality of grooves 906. The one or more openings 908 may extendthrough towards the second surface. The one or more openings 908 aresized and configured to receive at least a portion of a connectionmechanism 806 (see FIG. 8C).

The one or more grooves or channels 906 may have a groove width 922 anda groove height 924. By modifying the groove or channel width 922 andgroove or channel height 924, the flexibility of the fit pod 900changes. The larger the groove width 922 and groove height, the fit pod900 flexibility increases. The smaller the groove width 922 and grooveheight, the fit pod 900 flexibility decreases. The groove width 922changes from the flattened configuration at the neutral, uncoupledstate, to a smaller groove width 922 changing the fit pod 900 into acurved configuration. The collective groove width 922 of each of the oneor more grooves or channels 906 determines the inward curvature or theflexible distance once the second ends 916 of the grooves or channels906 abut or mate providing a positive stop. Furthermore, the fit pods900 can be provided in a series of overall sizes and/or thicknesses 920.The one or more fit pods 900 having a ¼″ thickness progressively up to a1.25″ or greater thickness 920 (preferably, 0.25 inches or greater).Desirably, the different thickness 920 fit pods can be provided withsimilar external dimensions (i.e., height and/or width), with only thethickness 920 differing to any substantial degree, allowing differentthickness fit pods to be “mixed and matched” for use with a singlehelmet, helmet liner or other component, and/or other item of protectiveclothing or equipment.

FIGS. 10A-10C depict various views of one embodiment of a connectionmechanism 1000. The connection mechanism 1000 having a height 1006, awidth 1004 and a depth 1010. The connection mechanism 1000 comprises abase 1012, a plurality of longitudinally extending members 1016, and aplurality of detents 1014. The longitudinally extending members 1016having a member thickness 1008 and a member width 1002, and each of thelongitudinally extending members 1016 extending longitudinally away fromthe base 1012 in the same plane of the base 1012. The longitudinallyextending members 1016 may be spaced apart from each other symmetricallyor asymmetrically. The longitudinally extending members 1016 may beplanar and/or flat. The plurality of detents 1014 extendsperpendicularly or substantially perpendicularly away from the base1012, which “substantially” means that the detents 1014 may have aslight oblique angle from 1 degree to 10 degrees from beingperpendicular. The plurality of detents 1014 may be positioned betweenthe longitudinally extending members 1016. Alternatively, the pluralityof detents 1014 may be aligned with the longitudinally extending members1016. The plurality of detents 1014 may arranged into a shape and/orcomprise a shape, the shape may match or substantially match the fit podconnection openings. The shape may comprise a circle, an oval, anellipse, a polygon and/or irregular polygon.

The plurality of detents 1014 having a first portion 1018 and a secondportion 1020, the second portion having a protrusion, where theprotrusion is larger than the connection mechanism opening 602 (see FIG.6A-6C), and the protrusion having a bottom surface that mates with anexternal surface of the inner shell or inner layer 600. The plurality ofdetents 1014 will flex inward when being inserted into the connectionmechanism opening 602, and once the plurality of detents 1014 arethrough, the plurality of detents 1014 will return to its unstressedstate by expanding, and the expansion will secure the connectionmechanism 1000 in place. Therefore, to remove the connection mechanism1000 from the inner shell or layer 600, the plurality of detents 1014can be pinched together to release. Accordingly, the detents 1014 canfacilitate the desired alignment. The detents 1014 intuitively allowsthe user to insert into the connection mechanism openings 602 (see FIGS.6A-6C) into a proper orientation and placement, resulting in little orno confusion for securing the pods to the inner shell or layer 600. Suchdesign of the connection mechanism 1000 and/or the detents 1014 alsoremove the ability of the fit pods to rotate.

In another embodiment, the connection mechanism 1000 may be coupled to afit pod 900 (see FIG. 9A-9H) to create a fit pod assembly 800 (see FIG.8A-8C). The connection mechanism 1000 may have a first portion and asecond portion. The first portion having a top surface and a bottomsurface. At least a portion of the second portion being inserted intothe connection mechanism opening 602 (see FIG. 6A-6C) of the inner shellor layer 600 until at least a portion of the second portion protrudesfrom the connection mechanism opening 602, and the top surface of thefirst portion mates with the inner surface of the inner shell or layer600. The bottom surface of first portion mates or coupled to fit pod 900bottom surface 910 (see FIG. 9A-9H). The connection mechanism 1000 maycomprise a polymer material known in the art. More specifically, thepolymer material allows sufficient flexibility and can withstandrepeated cycles of engagement and disengagement from the modular podand/or the helmet inner layer. Alternatively, other types of connectionmechanisms may be utilized, which include Velcro (hook and loop),adhesives, snaps, screws, press-fittings, magnetic mechanisms, and/orany combination thereof. Furthermore, the connection mechanism maycomprise an alignment feature, the alignment feature allows forintuitive placement of the fit pod assembly in the correct direction toprevent improper placement or orientation. Tactile feedback with a“snap” may be desired.

FIGS. 11A-11H depict various views of an alternate embodiment of a fitpod assembly 1100. The fit pod assembly 1100 may desirably comprise aflattened configuration or a curved configuration. The fit pod assembly1100 may comprise a fit pod and a connection mechanism 1106. The fit podassembly 1100 comprises a first portion 1102, a second portion 1104,and/or a connection mechanism 1106. The second portion 1104 extends islarger than the perimeter of the first portion 1102 to create a flange.The first portion 1102 comprises a plurality of channels 1108 disposedwithin, the plurality of channels 1108 may extend from the first portion1102 towards at least a portion of the second portion 1104. Theplurality of channels 1108 may be spaced apart from each othersymmetrically or non-symmetrically. At least one end of the plurality ofchannels 1108 may intersect at an intersection point 1110.

The fit pod comprises a generally triangular shaped body with roundedcorners (an isosceles triangle, for example), although a variety ofother shapes, including other shaped circles, triangles, squares,pentagons, hexagons, septagons and/or octagon shapes, could be utilizedin a variety of embodiments. In a similar manner, alternative shapeshaving rounded and/or sharp corners and/or edges may be utilized, aswell as irregular and/or re-entrant shaped bodies, if desired.Furthermore, as previously disclosed herein, the fit pods can beprovided in a series of overall sizes and/or thicknesses 1112. The oneor more fit pods having a ¼″ thickness progressively up to a 1.25″ orgreater thickness 1112 (preferably, 0.25 inches or greater). Desirably,the different thickness 1112 fit pods can be provided with similarexternal dimensions (i.e., height and/or width), with only the thickness1112 differing to any substantial degree, allowing different thicknessfit pods to be “mixed and matched” for use with a single helmet, helmetliner or other component, and/or other item of protective clothing orequipment.

FIGS. 12A-12B depicts an exploded and cross-sectional view of oneembodiment of a fit pod assembly 1200 of FIG. 11A-11H. The fit podassembly 1200 comprises a fit pod 1202 and a connection mechanism 1204.The fit pod 1202 comprises a top layer 1206, a bottom layer 1212, atleast one foam layer 1208, 1210, a connection mechanism 1204, and/or anycombination thereof. More specifically, the fit pod assembly 1200comprises a top layer 1206, a first foam layer 1208, a second foam layer1210, a bottom layer 1212, and a connection mechanism 1204. Furthermore,the fit pod assembly 1200 may further comprise an impact mitigationstructure (not shown) or an impact distribution plate (not shown),and/or an impact mitigation structure and an impact distribution plate,where the impact mitigation structure and/or the impact distributionplate are disposed between the top layer and/or bottom layer. The fitpod assembly 1200 may comprise a flattened or planar configuration,and/or a curved configuration. The at least one foam layer 1208, 1210and/or the first foam layer 1208 and the second foam layer 1210 may bedisposed between the top layer 1206 and the bottom layer 1212.

The at least one bottom layer 1212 or least one top layer 1206 maycomprise a foam layer or foam material, a plastic material, a resilientfabric that may be a two-way or four-way stretch material and/or anyelastic material. The plastic material may comprise an acrylic, apolypropylene, a polycarbonate, an acrylonitrile-butadiene-styrene, apolyethylene, a polyethylene terephthalate, and/or any combinationthereof. In one embodiment, the top layer and/or bottom layer maycomprise a 2-way or 4 way stretch fabric and a polymer film. The polymerfilms comprise a polyethylene film, polypropylene film, a polyurethanefilm, a nylon film, a polyester film, a polyvinyl chloride film and/orany combination thereof. The polymer film may be coupled or laminated tothe 2-way or 4-way stretch fabric. The at least one top layer 1206and/or at least one bottom layer 1212 may be the same material, or theymay be different materials. The at least one foam layer 1208,1210, thefirst foam layer 1208, a second foam layer 1210 may be the same foammaterial or different foam materials. The at least one foam layer 1208,1210 may further comprise a single, continuous piece and/or two or moresegmented pieces. The at least one bottom layer 1212 may comprise anopening 1214, the opening 1212 sized and configured to receive a portionof the connection mechanism 1204.

The at least one foam layer 1208, 1210 may comprise a single layer ormultiple layers, which any of the layers may be comprised of the same ordifferent various types of foam. In one example, the foam layer maycomprise a first foam layer and a second foam layer. The first foamlayer 1208 and/or a second foam layer 1210 may comprise of one singlelayer of foam, and/or a plurality of segmented foam components. Thefirst foam layer 1208 and/or second foam layer 1210 may be disposedbetween the at least one top layer 1206 and/or at least one bottom layer1212. The first foam layer 1208 and/or second foam layer 1210 may besized and configured to fit within the one or more recesses of the atleast one top layer 1206 and/or at least one bottom layer 1212. The atleast one foam layer 1208, 1210 can include polymeric foams, quantumfoam, polyethylene foam, thermoplastic polyurethane foam (foam rubber),XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, orgel), impact absorbing foam (e.g., VN600), latex rubber foam, convolutedfoam (“egg create foam”), Ariaprene, Evlon foam, impact hardening foam,4.0 Custula comfort foam (open cell low density foam), and/or anycombination thereof. The at least one foam layer 1208, 1210 may have anopen-cell structure or closed-cell structure. The at least one foamlayer 1208, 1210 can be further tailored to obtain specificcharacteristics, such as anti-static, breathable, conductive,hydrophilic, high-tensile, high-tear, controlled elongation, and/or anycombination thereof. The foam layer, each of the at least one foam layer1208, 1210 and/or the impact mitigation structure may have a thicknessranging from 0.5 mm to 25 mm.

The at least one bottom layer 1212 and/or the at least one top layer1206 can surround the complete perimeter of the at least one foam layer1208, 1210, and the connection mechanism 1204 completely enclosing thecomponents. The least one foam layer 1208, 1210, and the connectionmechanism 1204 may be freely “floating” between the at least one toplayer 1206 and the at least one bottom layer 1212. Alternatively, the atleast one bottom layer 1212 and/or the at least one top layer 1206 cansurround the complete perimeter of the impact mitigating structure, thedistribution plate and/or the at least one foam layer, completelyenclosing the impact mitigation structure leaving a flange around theperimeter.

FIGS. 13A-13H depicts various views of one embodiment of a top layer1300. The at least one top layer 1300 may have a top surface 1302 and abottom surface 1304. The opt surface 1302 having a plurality of channelsor grooves 1306, the plurality of channels 1306 extend from the topsurface 1302 towards a portion of the bottom surface 1304. The pluralityof channels 1306 may be spaced apart from each other symmetrically ornon-symmetrically. The plurality of channels having a channel depth 1308and a channel width 1310. The plurality of channels creates a pluralityof segments 1302. Each of the plurality of segments 1302 are by a gap,namely the channel width 1310. Furthermore, the at least one top layer1300 bottom surface 1304 having one or more recesses, the one or morerecesses having a single recess and/or two or more segmented recesses1312, the one or more recesses being sized and configured to receive atleast one foam layer 1208, 1210 (as shown in FIG. 12A-12C).Alternatively, the at least one top layer or at least one bottom layermay comprise a first surface and a second surface, a through-holethrough the first and second surfaces, the through-hole being sized andconfigured to receive at least a portion of the connection mechanism.

FIGS. 14A-14H depicts various views of an alternate embodiment of aconnection mechanism 1400. The connection mechanism 1400 comprises afirst portion 1404 and a second portion 1402. The first portion 1404having a planar with a triangular and/or generally triangular shape, butany shape may be contemplated. The shapes may comprise circles, ovals,ellipses, regular or irregular polygons, the regular polygons maycomprise a square, rectangle, pentagon, hexagon, septagon, octagon,nonagon, decagon, and/or any combination thereof. The connectionmechanism 1400 and/or the first portion 1404 comprises a first surface1406 and a second surface 1408. The first surface 1406 or the secondsurface 1408 may have the second portion 1402 extend longitudinally awayfrom the first portion 1404, the longitudinal extension includingperpendicular or substantially perpendicular from the first surface 1406or the second surface 1408. The second portion 1402 is sized andconfigured to fit within an opening 1214 of the bottom layer 1212 (seeFIG. 12C). Alternatively, the second portion 1402 may match orsubstantially match the one or more fit pod connection mechanismopenings on the inner layer. The second portion 1402 comprising aplurality of detent members 1410, the detent members 1410 may comprisebeveled edges 1412. The beveled edges 1412 facilitates easy insertionthrough the at least one opening 1214 of the bottom layer 1212 (see FIG.12C). The second portion 1402 may comprise a shape, the shape may matchor substantially match the one or more fit pod connection mechanismopenings. The shapes may comprise circles, ovals, ellipses, regular orirregular polygons, the regular polygons may comprise a square,rectangle, pentagon, hexagon, septagon, octagon, nonagon, decagon,and/or any combination thereof.

The connection mechanism 1400 is inserted through the at least oneopening 1214 of the bottom layer 1212 allowing the detent members 1410to flex inward until first surface 1406 of the first portion 1404 matesor abuts against the bottom layer 1212 top surface or bottom surface(not shown). Once the first portion 14014 mates or abuts against thebottom layer 1212 top surface or bottom surface, the detent members 1410will expand to return to its original position and should retain theconnection mechanism 1400 within the bottom layer 1212.

Alternatively, the connection mechanism 1400 may comprise a base 1404and a connection post 1402, the connection post 1402 extendslongitudinally away from the first 1406 or second surface 1408. Thelongitudinal extension may include substantially perpendicular to thefirst or second surface. At least a portion of the connection post 1402is disposed between the at least one top and/or at least one top layer,the at least a portion of the connection mechanism 1400 is coupled orremovably coupled to the helmet. The connection post 1402 may comprise ashape, the shape may match or substantially match the one or more fitpod connection mechanism openings. The shapes may comprise circles,ovals, ellipses, regular or irregular polygons, the regular polygons maycomprise a square, rectangle, pentagon, hexagon, septagon, octagon,nonagon, decagon, and/or any combination thereof. The helmet maycomprise an outer layer, an impact mitigation structure or impactmitigation layer, an optional inner layer, and/or any combinationthereof. The impact mitigation structure and/or impact mitigation layermay be disposed between an inner layer and the outer layer.Alternatively, the impact mitigation structure may be coupled to theouter layer or the inner layer. The connection mechanism 1400 maycomprise a polymer material known in the art. More specifically, thepolymer material can allow sufficient flexibility and can withstandrepeated cycles of engagement and disengagement from the modular podand/or the helmet inner layer. Alternatively, other types of connectionmechanisms may be utilized, which include Velcro (hook and loop),adhesives, snaps, screws, press-fittings, magnetic mechanisms, and/orany combination thereof. Furthermore, the connection mechanism maycomprise an alignment feature, the alignment feature allows forintuitive placement of the fit pod assembly in the correct direction toprevent improper placement or orientation. Tactile feedback with a“snap” may be desired.

FIGS. 15A-15H depicts various views of an alternate embodiment of a fitpod assembly 1500 that may include a curvature that conforms to aplayer's head. The fit pod assembly 1500 may comprise a curvedconfiguration, the curved configuration may conform to a player's head.The curved fit pod assembly 1500 comprises a fit pod 1502 and aconnection mechanism 1504. The fit pod assembly 1500 comprises a singlefoam layer construction, and/or a multi-layer construction. In oneembodiment, the fit pod assembly 1500 comprises a first portion 1506 anda second portion 1508, and/or a connection mechanism 1504. The secondportion 1508 is larger than the perimeter of the first portion 1506 tocreate a flange. The first portion 1506 having a plurality of channels1510 disposed within, the plurality of channels 1510 may extend from thefirst portion 1506 towards at least a portion of the second portion1508. The plurality of channels 1510 may be spaced apart from each othersymmetrically or non-symmetrically. At least one end of the plurality ofchannels 1510 may intersect at an intersection point 1512. The pluralityof channels 1510 having a channel depth 1514 and/or a channel width1516. Modifying the channel depth 1514 and/or the channel width 1516will alter the flexibility of the fit pod 1502. Larger channel depth1514 and width 1516 would increase the flexibility. In contrast, smallerchannel depth 1514 and width 1516 would decrease the flexibility of thefit pod 1502.

The fit pod 1502 comprises a generally triangular shaped body withrounded corners (an isosceles triangle, for example), although a varietyof other shapes, including other shaped triangles, squares, pentagons,hexagons, septagons and/or octagon shapes, could be utilized in avariety of embodiments. In a similar manner, alternative shapes havingrounded and/or sharp corners and/or edges may be utilized, as well asirregular and/or re-entrant shaped bodies, if desired. Furthermore, aspreviously disclosed herein, the fit pods 1502 can be provided in aseries of overall sizes and/or thicknesses 1518. The one or more fitpods 1502 having a ¼″ thickness progressively up to a 1.25″ or greaterthickness 1518 (preferably, 0.25 inches or greater). Desirably, thedifferent thicknesses 1518 of the fit pods 1502 can be provided withsimilar external dimensions (i.e., height and/or width), with only thethickness 1518 differing to any substantial degree, allowing differentthickness fit pods 1502 to be “mixed and matched” for use with a singlehelmet, helmet liner or other component, and/or other item of protectiveclothing or equipment. The mixing and matching also comprise bothflattened and/or curved configuration of fit pods 1500.

In another embodiment, the fit pod 1502 comprises a top layer, a bottomlayer, at least one foam layer, a connection mechanism 1504, and/or anycombination thereof. More specifically, the curved fit pod assemblycomprises a top layer, a first foam layer, a second foam layer, a bottomlayer, and a connection mechanism 1504. Furthermore, the fit podassembly may further comprise an impact mitigation structure (not shown)or an impact distribution plate (not shown), and/or an impact mitigationstructure and an impact distribution plate, where the impact mitigationstructure and/or the impact distribution plate are disposed between thetop layer and/or bottom layer. The first foam layer, the second foamlayer, and a portion of the connection mechanism 1504 may be disposedbetween top layer and the bottom layer. The top layer and the bottomlayer may be the same material, or they may be different materials. Thetop layer and/or the bottom layer comprises a 2-way stretch fabric, a4-way stretch fabric, a polycarbonate material, a foam material, and/orany combination thereof.

The plastic material may comprise an acrylic, a polypropylene, apolycarbonate, an acrylonitrile-butadiene-styrene, a polyethylene, apolyethylene terephthalate, and/or any combination thereof. In oneembodiment, the top layer and/or bottom layer may comprise a 2-way or 4way stretch fabric and a polymer film. The polymer films comprise apolyethylene film, polypropylene film, a polyurethane film, a nylonfilm, a polyester film, a polyvinyl chloride film and/or any combinationthereof. The polymer film may be coupled or laminated to the 2-way or4-way stretch fabric. The first foam layer and the second foam layer maybe the same foam material or different foam materials. The foam materialmay comprise polymeric foams, quantum foam, polyethylene foam,thermoplastic polyurethane foam (foam rubber), XPS foam, polystyrene,phenolic, memory foam (traditional, open cell, or gel), impact absorbingfoam (e.g., VN600), latex rubber foam, convoluted foam (“egg createfoam”), Ariaprene, Evlon foam, impact hardening foam, 4.0 Custulacomfort foam (open cell low density foam) and/or any combinationthereof. The at least one foam layer may have an open-cell structure orclosed-cell structure. The at least one foam layer can be furthertailored to obtain specific characteristics, such as anti-static,breathable, conductive, hydrophilic, high-tensile, high-tear, controlledelongation, and/or any combination thereof.

FIGS. 16A-16D depict various views of another exemplary embodiment of amodular fit pod assembly 1600. The modular pod fit pod assembly 1600comprises a fit pod 1602 and a connection mechanism 1604. The connectionmechanism 1604 coupled to the fit pod 1602. In one embodiment, the fitpod 1602 comprises a single foam layer. The single foam layer may bemolded or thermoformed into a desired shape. The shape may be triangularor generally triangular, where the corners become sharp angled cornersto rounded corners. Other shapes may be contemplated, such a as regularor irregular polygons. The single foam layer may comprise a foammaterial as shown FIG. 16F. The at least one foam layer or foam materialcan include polymeric foams, quantum foam, polyethylene foam,thermoplastic polyurethane foam (foam rubber), XPS foam, polystyrene,phenolic, memory foam (traditional, open cell, or gel), impact absorbingfoam (e.g., VN600), latex rubber foam, convoluted foam (“egg createfoam”), Ariaprene, Evlon foam, impact hardening foam, 4.0 Custulacomfort foam (open cell low density foam) and/or any combinationthereof. The at least one foam layer may have an open-cell structure orclosed-cell structure. The at least one foam layer can be furthertailored to obtain specific characteristics, such as anti-static,breathable, conductive, hydrophilic, high-tensile, high-tear, controlledelongation, and/or any combination thereof.

The fit pod 1602 may comprise a top surface 1606 and a bottom surface1608. The top surface 1606 having a plurality of channels or grooves1610 disposed within, the plurality of channels 1610 having a channelwidth and channel depth. The plurality of channels 1610 are spaced apartfrom each other symmetrically or asymmetrically. The spaced partplurality of channels 1610 may segment the top surface 1606 into two ormore segmented surfaces. The plurality of channels 1610 may extend fromthe top surface 1606 towards a portion of the bottom surface 1608. Theplurality of channels 1610 may comprise at least one end that intersectsat an intersection point 1612. The connection mechanism 1604 is thesimilar or same connection mechanism disclosed in FIGS. 10A-10C. Theconnection mechanism 1604 being coupled to the bottom surface 1608 ofthe fit pod 1602. More specifically, the connection mechanism 1604having a top surface and a bottom surface. The bottom surface of theconnection mechanism 1604 being coupled to the bottom surface 1608 ofthe fit pod 1602. The top surface of the connection mechanism 1604 mayhave a detent body extending perpendicularly or substantiallyperpendicular (being 1 to 15 degrees oblique from perpendicular) fromthe top surface. In addition, the fit pods 1602 may further comprise aplurality of vent openings 1614. The vent openings 1614 may extendthrough the bottom surface 1608 of the fit pod 1602. The vent openings1614 may be disposed within the plurality of channels 1610.

The connection mechanism 1604 having connection features for attachingto a helmet. The connection features comprise a series of snap-locktabs, shown in a triangular configuration, with each tab including aflexible body and a terminal flange which can engage with acorresponding opening and/or surface(s) within triangular openings inthe helmet inner shell (see FIGS. 10A-10C) or other structural layer(not shown). Desirably, the snap-lock tabs are bonded to the modularpods and are shaped and configured to be inserted into corresponding atleast one or more openings within the inner shell, and one or more innerlayer holes within the helmet inner shell, with the engagementpreventing the pods from rotating and/or disengaging from the shell orother helmet component in an unwanted manner. If removal of anindividual pod is desired, the tabs can be flexed inward and releasedfrom the liner hole in a known manner, and the fit pod and/or fit podassembly removed from the shell. In various alternative embodiments, awide variety of other fastening arrangements for the pods could beutilized, as known in the art, including interference fit geometryand/or a directional slide (among others).

In one embodiment, the fit pods 1602 can be provided in a series ofsizes and/or thicknesses as shown in FIG. 16G. For example, a first pod1616 having a ¼″ thickness progressively up to a fourth pod 1622 with 1″or 1.25″ or greater thickness (preferably, 0.25 inches or greater).Desirably, the different thickness triangular pods 1616, 1618, 1620,1622 can be provided with similar external dimensions (i.e., heightand/or width), with only the thickness differing to any substantialdegree, allowing different thickness fit pods to be “mixed and matched”for use with a single helmet liner or other component, and/or other itemof protective clothing.

FIGS. 17A-17H depict various views of an alternate embodiment of a fitpod assembly 1700. The modular pod fit pod assembly 1700 comprises a fitpod 1702 and a connection mechanism 1704. The connection mechanism 1704coupled to the fit pod 1702. In one embodiment, the fit pod 1702comprises a single foam layer. The single foam layer may be molded orthermoformed into a desired shape. The shape may be triangular orgenerally triangular, where the corners become sharp angled corners torounded corners. Other shapes may be contemplated, such a as regular orirregular polygons. The single foam layer may comprise a foam material.The modular fit pod 1702 may further comprise a single impact mitigationstructure (not shown), optionally without a top or bottom layer. The atleast one foam layer or foam material can include polymeric foams,quantum foam, polyethylene foam, thermoplastic polyurethane foam (foamrubber), XPS foam, polystyrene, phenolic, memory foam (traditional, opencell, or gel), impact absorbing foam (e.g., VN600), latex rubber foam,convoluted foam (“egg create foam”), Ariaprene, Evlon foam, impacthardening foam, 4.0 Custula comfort foam (open cell low density foam)and/or any combination thereof. The at least one foam layer may have anopen-cell structure or closed-cell structure. The at least one foamlayer can be further tailored to obtain specific characteristics, suchas anti-static, breathable, conductive, hydrophilic, high-tensile,high-tear, controlled elongation, and/or any combination thereof.

The fit pod 1702 may comprise a top surface 1706 and a bottom surface1708. The top surface 1706 having a plurality of channels or grooves1710 disposed within, the plurality of channels 1710 having a channelwidth and channel depth. The plurality of channels 1710 are spaced apartfrom each other symmetrically or asymmetrically. The spaced partplurality of channels 1710 may segment the top surface 1706 into two ormore segmented surfaces. The plurality of channels 1710 may extend fromthe top surface 1706 towards a portion of the bottom surface 1708. Theplurality of channels 1710 may comprise at least one end that intersectsat an intersection point 1712. The connection mechanism 1704 is thesimilar or same connection mechanism disclosed in FIGS. 14A-14H. Theconnection mechanism 1704 being coupled to the bottom surface 1708 ofthe fit pod 1702. More specifically, the connection mechanism 1704having a top surface and a bottom surface. The bottom surface of theconnection mechanism 1704 being coupled to the bottom surface 1708 ofthe fit pod 1702. The top surface of the connection mechanism 1704 mayhave a detent body extending perpendicularly or substantiallyperpendicular (being 1 to 15 degrees oblique from perpendicular) fromthe top surface. Accordingly, the detents body can facilitate thedesired alignment. The detents body intuitively allows the user toinsert into the connection mechanism openings into a proper orientationand placement, resulting in little or no confusion for securing the podsto the inner shell or layer. Such design of the connection mechanism1704 and/or the detents body also remove the ability of the fit pods torotate. The detent body having a shape, the detent body shape matchingor substantially matching the connection mechanism opening in the innershell or layer to prevent misalignment, misplacement or improperorientation. Alternatively, the detent body being shaped and configuredto be disposed within the connection mechanism opening of the innershell or layer to prevent misalignment, misplacement or improperorientation. In addition, the fit pods 1702 may further comprise aplurality of vent openings (not shown). The vent openings may extendthrough the bottom surface 1708 of the fit pod 1702. The vent openingsmay be disposed within the plurality of channels 1710.

In one embodiment, fit pods 1702 can be provided in a series of sizesand/or thicknesses. For example, a first pod having a ¼″ thicknessprogressively up to a fourth pod with 1″ or 1.25″ or greater thickness(preferably, 0.25 inches or greater). Desirably, the different thicknesstriangular pods can be provided with similar external dimensions (i.e.,height and/or width), with only the thickness differing to anysubstantial degree, allowing different thickness fit pods to be “mixedand matched” for use with a single helmet liner or other component,and/or other item of protective clothing.

In one exemplary embodiment, an improved helmet system may comprisefeatures to help protect against oblique, tangential and/or rotationalacceleration as shown in FIG. 18A-18E and FIG. 19 . The improved helmetsystem may comprise a helmet, one or more modular fit pod assemblies1800 and/or fit pod layer(s). The one or more fit pod assemblies 1800and/or fit pod layer comprises a fit pod, a connection mechanism, and anelastomeric support mechanism. Alternatively, the improved helmet systemmay comprise a helmet, one or more impact mitigation structures, and/oran elastomeric support mechanism. The helmet may include an outer layer.The helmet may further comprise an inner layer and/or an impactmitigation layer disposed on an inner surface of the outer layer, and/orbetween the outer layer or inner layer, and/or any combination thereof.The fit pod layer may comprise one or more modular fit pod assemblies.Each of the fit pod assemblies 1800, 1810, 1812, 1818 may also include afit pod 1802, a connection mechanism 1804, and an elastomeric supportmechanism or structure 1806, 1820. The fit pod 1802 may further comprisea top surface (not shown) and a bottom surface (not shown). The one ormore fit pods may comprise a single layer foam material and/or amulti-layered foam material construction as disclosed herein.

The one or more fit pod assemblies 1800, 1810, 1812, 1818 may furthercomprise a low-friction layer 1808, the low friction layer 1808facilitates the sliding of the elastomeric support structure 1806, 1820with the connection mechanism 1804 relative to the fit pod 1802. The lowfriction layer 1808 comprises PTFE, polyimide, PEEK, PPS, Nylon, Acetal,Polyester, and/or any other low-friction materials known in the art. Thelow friction layer 1808 may further comprise a lubricant to enhance thelow-friction properties. The low-friction layer 1808 may be coupled tothe bottom surface of the fit pod 1802. The low-friction layer 1808 maymatch or substantially match the perimeter of the fit pod 1802. The lowfriction layer 1808 may extend beyond the perimeter of the fit pod 1802to produce a flange or edge.

The elastomeric support mechanism allows the one or more fit podassemblies 1800, 1810, 1812, 1818 to be slidably movable from a firstposition to a second position. The elastomeric support mechanism 1806,1820, links the fit pod 1802 to connection mechanism. The elastomericsupport mechanism 1806, 1820 may be adjusted in stiffness to allow thefit pod 1802 to slide in shear when desired during in impact to thehelmet. The elastomeric support structure stretches and/or articulatesto allow the shear sliding of the fit pod 1802 relative to theelastomeric support mechanism 1806, 1820 during impact and then returnsthe fit pod 1802 back to the original neutral position after the impact.The first position which the connection mechanism 1804 is positioned ina neutral position, to a second position, which the connection mechanism1804 is posited laterally from the neutral position. The elastomericsupport mechanism may be removably coupled or integrally coupled to theeach one or more fit pods 1802. The addition of an elastomeric supportmechanism 1806, 1820 to one or more fit pods and/or one or more impactmitigation layers is advantageous over traditional helmets. Suchelastomeric support mechanism 1806, 1820 facilitates sliding or lateralmovement of the fit pod assembly relative to the head of the wearerrather than outer shell of the helmet relative to the head or outershell of the helmet relative to an inner shell.

The elastomeric support mechanism 1806, 1820 may comprise an comprisesan elastomeric material with elastomeric properties. The elastomericmaterial may be rubber materials or thermoplastic elastomers. Theelastomeric structure may comprise elastomeric frame or structure 1806,a woven elastomeric fabric or cover (such as a 2-way or 4-way stretchfabric), an fabric or cover 1820 with elastomeric properties (e.g. awoven, knit graft), and/or one or more springs (not shown). For example,in one embodiment, the elastomeric mechanism 1806 may comprise a frame1810, a base 1814, and a plurality of struts 1812. The frame 1810 isshaped and configured to match or substantially match the perimeter ofeach of the one or more fit pods 1802. The substantially match maycomprise a perimeter that may be offset from 1-5 mm from the perimeteredge of each of the one or more fit pods.

The one or more struts and/or the plurality of struts 1812 having alength, a first end and a second end. The first end of the one or morestruts is coupled to a portion of the frame 1810, and the second end iscoupled to a portion of the base 1814. The one or more struts 1812 mayhave a variety of configurations, along the length. The configurationsmay include a uniform straight strut, curved strut, undulated strut,and/or any combinations thereof. The configurations along the length maybe modified, adjusted and/or tuned to customize the allowable sheardistance (or lateral distance) that may be acceptable for the particularsport and/or rotational motion. The one or more struts 1812 may furthercomprise one or more elastomeric transitions that has differentelastomeric modulus, tensile stiffness, elastic properties, and/orflexibility when under tension. For example, the one or more struts 1812may comprise a first portion, and a second portion. The first portionand the second portion may be different elastomeric materials withdifferent properties, or they may comprise the same material with sameproperties. The first portion may have a first transition with stifferelastomeric property than the second portion having a second transition.The elastomeric mechanism or structure may comprise differentelastomeric materials, such as rubber, rubber blends, thermoplasticelastomers, and/or any elastomeric material, or material withelastomeric properties that contains elastic recovery after deformationin compression or tension. The base 1814 may further comprise posts1816. The posts 1816 extend perpendicularly away from the base 1814. Atleast a portion of the posts 1816 are sized and configured to fit withinone or more openings on the connection mechanism 1804. The elastomericstructure 1806 may be coupled to the low friction layer 1808 and/or itmay be coupled onto the fit pod 1802 directly.

The connection mechanism 1804 may be coupled onto the elastomericmechanism 1806. The connection mechanism 1804 may have a shape thatmatches or substantially matches the perimeter of the fit pod 1802.Alternatively, the shape may comprise a polygon or an irregular polygon.The connection mechanism 1806 comprises a first portion 1826 and asecond portion 1822. The first portion 1826 may include a plurality ofopenings 1824, the plurality of openings 1824 sized and configured toreceive at least a portion of the posts 1816 to secure the connectionmechanism 1826. The second portion 1822 extends perpendicularly awayfrom the first portion 1822, the second portion 1822 sized andconfigured to fit within the connection mechanism openings within theinner layer or inner shell (not shown).

In another embodiment, the elastomeric support mechanism 1806 maycomprise a flexible, elastomeric cover 1820. The fit pod 1802 and/or aportion of the connection mechanism 1804 may be disposed within theelastomeric cover 1820. The elastomeric cover 1820 may enclose theentirety of the fit pod 1802 and/or at least a portion of the fit pod1802. In an alternative embodiment, the elastomeric support mechanism1806 may comprise both an elastomeric cover 1820 and an elastomericstructure 1806.

FIGS. 19A-19C illustrates cross-sectional views of one embodiment of aprotective helmet system 1900 with a fit pod assembly 1918 with shear orsliding properties. The protective helmet system 1900 may comprise ahelmet 1902 with an inner surface 1906 and an outer surface 1906. Thehelmet may further comprise an outer layer, the outer layer having aninner surface and an outer surface. The protective helmet system mayfurther comprise an impact mitigation layer, the impact mitigation layerbeing coupled to the inner surface of the outer layer 1. The protectivehelmet system 1900 may further comprise an inner layer, the inner layerhaving an external surface and an internal surface. The external surfaceof the inner layer being coupled to the impact mitigation layer. Theimpact mitigation layer being disposed between the outer layer and theinner layer. Such a protective helmet system 1900 with a fit podassembly 1918 with shear or sliding properties allows for helmet fitadjustment for different wearer's and creates a shear sliding capabilitybetween the head and the outer surface of the helmet to mitigate some ofthe rotational, tangential forces that may be present during an impact.A plurality of fit pod assemblies 1918 may be disposed within the helmet1900.

The fit pod assembly 1918 may comprise a fit pod, a low friction layer1910 and a connection mechanism 1908 and an elastomeric supportmechanism 1910. The connection mechanism 1908 will be used as aretention mechanism for the fit pod assembly 1918 to be attached orcoupled firmly to an inner surface of the helmet. The connectionmechanism 1908 will have features that make it removable from the innersurface of the helmet to be replaced by another pod for enhanced orimproved fit to the wearer—different thicknesses, shapes may be used for“mix-and-match.” The connection mechanism 1908 may be a detent snap,screw, hook and loop, and/or any other fastener known in the art.

The low friction layer 1912 may be coupled to the fit pod. The lowfriction layer 1912 allows the connection mechanism 1908 to slide freelyon a surface of the fit pod with minimal friction. The coefficient offriction between the low friction layer 1912 and the connectionmechanism 1908 may be adjusted to allow desired shear sliding tailoredfor specific impact forces. The elastomeric support mechanism 1910 linksthe fit pod to the connection mechanism 1808. The elastomeric supportmechanism 1910 may be adjusted in stiffness to allow the fit podassembly 1918 to slide in shear when desired during an impact to thehelmet (see FIG. 19B). The elastomeric support mechanism 1910 stretchesand/or articulates to allow the shear sliding during impact and thenreturns the fit pod to the original, neutral location after impact. (seeFIG. 19C) The elastomeric support mechanism 1910 may comprise anelastomeric polymer, a woven elastomeric fabric, a spring mechanism,and/or any combination thereof. At least a portion of the elastomericsupport system 1910 is coupled to at least a portion of the low frictionlayer 1912.

The fit pods may comprise a first foam layer 1914 and a second foamlayer 1916. The first 1914 and second foam layers 1916 may comprisedifferent foam materials and/or the same foam materials. The first foamlayer 1914 and the second foam layer 1916 may have properties for bothcomfort and impact mitigation. Alternatively, the fit pod may compriseat least one foam layer, the at least one foam layer may be a singlefoam material, or multi-layered construction. The at least one foamlayer, the first foam layer 1914 and/or the second foam layer 1916 maycomprise foam material that is designed to collapse, fold, deform and/orbuckle when pressure or impacts are applied. The at least one foammaterial layer, the first foam layer 1914 and/or the second foam layer1916 thickness can be adjusted to optimize the fit for the wearer.

FIGS. 20A and 20B depict exemplary embodiments of a plurality of modularfit pods and/or fit pod assemblies 2004 coupled to an inner surface of ahelmet 2002 in various desired positions. The helmet 2002 comprises anouter layer. The helmet 2002 may further comprise an impact mitigationlayer, the impact mitigation layer coupled to an inner surface of theouter layer. The helmet 2002 may further comprise an inner layer, theinner layer having an external surface and an internal surface, theinner layer external surface coupled to a portion of the impactmitigation layer and/or the outer layer. In one exemplary embodiment,the plurality of fit pods or fit pod assemblies 2004 may be removablycoupled to the inner layer, liner and/or helmet outer layer. Theplurality of fit pods and/or fit pod assemblies 2004 may comprisedifferent sizes, shapes and thickness and may be used to retrofitcurrent commercially available helmets and/or liners leading to a morecustomized helmet and/or may be standard sizes used for a standardhelmet. Standard helmet sizes may include small, medium, large andextra-large. Each of the standard sizes may include a plurality ofmodular fit pods and/or fit pod assemblies.

For example, the standard small helmet size may comprise at least 7modular fit pods and/or fit pod assemblies 2004, where 6 modular fitpods and/or fit pod assemblies are removably connected and one modularpod is fixed as shown in FIGS. 20A and 20B. In alternative embodiments,other numbers and/or arrangements of fit pods and/or fit pod assemblies2004 could be provided, including the use of more and/or less fit podsor fit pod assemblies 2004 within a given helmet 2002 and/or helmetliner. Desirably, the different sized helmet layers would beaccommodated by differently spaced, oriented and/or positioned modularfit pods and/or fit pod assemblies 2004 of identical length and/orheight. To accommodate differently shaped heads, one of more of themodular fit pods and/or fit pod assemblies 2004 in a given helmet innershell can be replaced with a modular fit pods and/or fit pod assemblies2004 of similar height/length but differing thickness. With fourdifferent thicknesses of modular fit pods and/or fit pod assemblies 2004to choose from, the present system allows a single helmet shell toprovide over 4000 different pad combinations. Where an exemplary helmetsystem included small, medium, large and extra-large helmet shells with6 replaceable modular fit pods and/or fit pod assemblies 2004 each, thissystem could provide over 16,000 combinations to accommodate virtuallyany head size and/or shape. In at least one alternative embodiment, ahelmet system could include a small shell with 5 or 6 replaceablemodular fit pods and/or fit pod assemblies, medium and/or large shellswith 6 replaceable modular fit pods and/or fit pod assemblies each, andan XL shell with 6 or 7 replaceable modular fit pods and/or fit podassemblies.

In various embodiments, each helmet 2002 and/or helmet liner size (i.e.,small, medium, large and extra-large) could include at least onenon-removable fit pod and/or fit pod assemblies 2004 (i.e., the frontalpod), which can comprise a pad having a ½″ thickness at a centrallocation, tapering down to ¼″ thickness at the offset sides.Alternatively, the frontal fit pod and/or fit pod assembly could beremoveable and/or replaceable, if desired, including the ability tochange the thicknesses of the front pods and/or front fit pod assemblyin a manner similar to those described with the other modular fit podsand/or fit pod assembly herein. If desired, the frontal fit pod and/orfrontal fit pod assembly could include optionally replaceable thinand/or thick versions, including versions to accommodate unusual fitcircumstances.

If desired, the front fit pod and/or front fit pod assembly couldutilize a snap-fit connection to the shell (which could be similar tovarious other modular pod connections described herein), or the frontfit pod and/or the frontal fit pod assembly could be attached to theshell by hook and loop type fasteners and/or held in by a cloth pouchattached to the front bumper and/or the shell using Velcro or some otherfastening mechanism. Alternatively, other types of connection mechanismsmay be utilized, which include Velcro (hook and loop), adhesives, snaps,screws, press-fittings, magnetic mechanisms, and/or any combinationthereof.

By providing 4 modular fit pods and/or fit pod assemblies 2004 ofsimilar height and length, in 4 different thicknesses (i.e., ¼″, ½″, ¾″and 1″ thicknesses), along with four different helmet liner sizes (i.e.,small, medium, large and extra-large), the present system significantlyreduces the cost and complexity of the system and its components(although the use of various other numbers of pod sizes and/or shellsizes is contemplated herein, including 2 sizes and/or 5 sizes of podsand/or shells). The modular fit pods and/or fit pod assemblies 2004themselves can be manufactured in bulk, with each thickness changetypically requiring little or no modification to the manufacturingand/or processing equipment, which greatly reduces the cost-per-unit foreach modular pod. Moreover, an equipment manager would only need tostockpile four different shell sizes, along with some modular pads ofthe four differing thicknesses (i.e., a small bag of each size), whichcould be altered and interchanged at will to fit each player. In asimilar manner, only a few liner sizes need be stockpiled to accommodatea wide range of players, such as S/M and L/XL liners for the S, M, Lyouth helmet and one liner for the M, L, XL varsity helmet, if desired.

If desired, the modularity of the fit pods and/or fit pod assemblies2004 could provide “position-specific” features for a player wishing toprovide supplemental and/or particularized protection with one or moreenhanced principal impact zones and/or impact types that can beparticularized to a specific player-position and/or the individualbehavior of a specific player (i.e., supplemental protection from one ormore directions and/or types of impacts that may be anticipated based onthe player's position and/or type of play). For example, a player maywish to incorporate additional impact protection into a right side ofthe player's helmet, such as where the player tends to “lead with theirright” in impact situations and/or where the location of the player'sposition tends to lead to a greater magnitude of right side impacts(i.e., the right-side guard position). If desired, the speed, direction,and magnitude of impact and/or player force could be collected duringeach player activity and analyzed to tailor impact protective elementsfor the specific player position.

In order to increase the amount of protection on the right side of thehelmet, the player may simply replace one or more of the modular fitpods and/or fit pod assemblies 2004 on the right side of the helmet 2002and/or helmet liner with thicker fit pods and/or fit pod assemblies2004, which could include replacement of modular fit pods and/or fit podassemblies 2004 of the left helmet side with thinner fit pods (tobalance the width reduction) and/or fit pod assemblies. Alternatively,the player may choose an “oversized” liner and/or helmet which may beslightly “too big” for the player, and then the player can replace themodular pods in one or more locations with thicker fit pods (to increasethe impact absorbing layer depth and also to “fit” the helmet moreappropriately) and/or fit pod assemblies.

The one or more modular fit pod assemblies may be desirably positionedaround various locations of the wearer's head, such as covering much ofthe area between an inner shell of the helmet and the user's head. Suchplurality of fit pod assemblies may include one or more of thefollowing: a frontal assembly (or front), a crown assembly, an occipitalassembly (or lower-back), a mid-back assembly, a parietal assembly (ormidline), and a temporal assembly (right and/or left sides), and/or anycombination(s) thereof. At least a portion of the fit pod assemblies maybe removably coupled to at least one inner layer, impact mitigationlayer, outer layer and/or any combination thereof to facilitate energyabsorption, reduce angular motion and/or rotational motion of the wearerafter impact, enhance fit and comfort.

The fit pod and/or fit pod assemblies may be manufactured in differentways. In one embodiment, the fit pod may comprise a top layer, a bottomlayer, and at least one foam layer. The at least one foam layer isdisposed between the top layer and bottom layer. Disposed being“free-floating” between the top and bottom layer and/or coupled to thetop and/or bottom layer. The at least one foam layer may comprise afirst foam layer and a second foam layer. The at least one foam layermay be a single, continuous piece of foam material. Alternatively, theat least one foam layer may be two or more segmented pieces of foammaterial. The top layer and the bottom layer may be the same materialsor may be different materials. The top layer may be coupled to thebottom layer. The coupling may include adhesive, Velcro, ultrasonic orimpulse welding, stitching, heat sealing, heat or hot melt, vacuumedformed, thermoformed, and/or any combination thereof.

Comfort Liner Assemblies

FIG. 21A-21C depicts one exemplary embodiment of an improved, one-piececomfort liner 2100, which can be utilized in conjunction with thevarious embodiments described herein. In this embodiment, the comfortliner 2100 can wrap around the wearer's head and fit within an innerlayer and/or an interior surface of a helmet which can desirably improvethe comfort and fit of the helmet system on the player or wearer. Thecomfort liner 2100 may comprise a plurality of comfort liner pads 2104,at least one base layer 2110, and a plurality of fit tabs 2102. Theplurality of comfort liner pads 2104 can be positioned and/or coupledonto the at least one base layer 2110, where each of the plurality ofcomfort pads 2104 are positioned adjacent to each other with a gapdistance 2112. The gap distance 2114 may be between 2 mm to 20 mm, whichthe gap distance 2114 facilitates flexibility when conforming to aplayer's or wearer's head. Each of the plurality of comfort pads 2104may be placed in specific regions within the helmet, such as at leastone frontal region (or front), an occipital region (or lower-back), amid-back region, a parietal region (or midline), and a temporal region(right and/or left sides), and/or any combination(s) thereof. The fittabs 2102 may be integrated with the at least one base layer 2110,and/or may be a separate piece that is coupled to the at least one baselayer 2110. The plurality of comfort pads 2104 may further includetemple pads 2106 (on left and right sides). The fit tabs 2102 areconnection mechanisms are desirably placed around the perimeter of thecomfort liner to help with securement of the comfort liner to itselfand/or the helmet. The plurality of comfort pads 2104 may be coupledonto the at least one base layer 2110 leaving an edge or flange 2114.The edge or flange may have a width of 2 mm to 20 mm. alternatively, thecomfort liner 2100 may be separated into two or more pieces. Forexample, the comfort liner 2100 may be separated into front portion anda back portion and may be segmented along an axis 2108.

FIG. 21C depicts a cross-sectional view of one exemplary embodiment of acomfort pad 2104 coupled onto the at least one base layer 2110. Thecomfort pad may comprise at least one foam layer 2116 and a top layer2118. The top layer 2118 and the at least one foam layer 2116 mayutilize different materials or the same materials. The top layer 2118may be an flexible material, an elastic material, a plastic or fabricidentification label layer, an over-layer of soft leather, a felt or asimilar polymer (i.e., a skin contact layer), an adhesive layer, a foammaterial (i.e., Confor slow recovery CF 47 medium foam commerciallyavailable from the Aero Technologies division of 3M Corporation, St.Paul, MN USA—and/or other open-cell polyurethane foam such as 4.0Custula open cell foam), a layer of perforated and/or non-perforatedimpact resistant polymer foam 1825 (i.e., Poron XRD urethane basedpolymer—commercially available from Rogers Corporation of Rogers, CT,USA), an under-layer of adhesive, a flexible rubber sealant layer orfabric backing (not shown) which may optionally be sealed and/orunsealed, an optional elastic connector layer, an optional plastic orfabric identification label layer and an optional cast substrateconnector layer, if desired. Furthermore, the comfort pad 2104 mayfurther comprise an impact mitigation layer and/or structure (notshown). In a similar manner, the remaining components of the pods and/orliner assemblies could include comfort or impact absorbing pads and/orother structures incorporating a similar combination and/or arrangementof materials and/or other materials, if desired. The comfort pad 2104may have a desired thickness 2120, the thickness can range from 5 mm to20 mm. FIGS. 22A-22B illustrate an alternate embodiment of a comfortliner.

FIG. 23 depicts a front view of another alternate embodiment of acomfort liner 2300. The comfort liner 2300 may comprise a plurality ofcomfort liner pads 2304, at least one base layer 2306, and a pluralityof fit tabs 2302. The plurality of comfort liner pads 2304 can bepositioned and/or coupled onto the at least one base layer 2306, whereeach of the plurality of comfort pads 2304 are positioned adjacent toeach other with a gap distance. The gap distance may be between 2 mm to20 mm, which the gap distance facilitates flexibility when conforming toa player's or wearer's head. Each of the plurality of comfort pads 2304may be placed in specific regions within the helmet, such as at leastone frontal region (or front), an occipital region (or lower-back), amid-back region, a parietal region (or midline), and a temporal region(right and/or left sides), and/or any combination(s) thereof. Theplurality of comfort pads 2304 may further include temple pads. The fittabs 2302 are connection mechanisms are desirably placed around theperimeter of the comfort liner 2300 to help with securement of thecomfort liner 2300 to itself and/or the helmet. The fit tabs 2302 mayflexible and/or elastic may include a retention mechanism, the retentionmechanism may comprise a Velcro (hook & loop) connection, snap, detent,adhesive and/or any combination thereof. The Velcro connection may allowfor coupling the comfort liner 2300 together and dispose within thehelmet. The flexible member and/or retention mechanism may be coupled tothe fit tabs 2302, coupling may occur through stitching and/or anymethods known in the art. The flexible member and/or retention mechanismmay be elastic to allow for adaptation to size of helmet or player'shead. In various embodiments, the various components described hereincan include a variety of arrangements and/or designs for the variouscomfort liner assemblies and each of the plurality of modular fit pods,fit pod assemblies, comfort pads and/or associated components. FIGS.24A-25B depict another alternate embodiment of a comfort liner.

FIG. 24A-24C depicts various views of one embodiment of a protectivehelmet system 2400. The protective helmet system 2400 comprises a helmet2402, a plurality of fit pod assemblies (not shown) and a comfort liner2406. The comfort liner 2406 may be desirably manufactured flat asdisclosed herein in FIGS. 21A-21C, 22A-22B, and 23 , then the comfortliner 2406 is folded to conform to the head of a wearer, and insertedwithin an interior surface of a helmet 2402. The plurality of comfortpads 2410 having a perimeter edge 2412, and each of the plurality ofcomfort pads 2410 are spaced apart from each other. The spacing apartfrom each other requires that the perimeter edges 2412 are alignedparallel to each other. The fit tabs 2408 of the comfort liner 2406 areused to couple to at least a portion of the helmet to secure in place.The comfort liner 2406 further comprises an additional space 2414 shouldelasticity is required—it can be further coupled to the comfort liner2406 and/or integrated with the comfort liner 2406. The helmet 2402 maycomprise an outer layer, the outer layer having an inner surface and anouter surface. The helmet may further comprise an impact mitigationlayer, the impact mitigation layer being coupled to an inner surface ofan outer layer. The helmet 2402 may further comprise an inner layer, theinner layer having an external surface and an inner surface, theexternal surface coupled to the impact mitigation layer. The impactmitigation layer may comprise a plurality of impact mitigationstructures and/or a plurality of fit pod assemblies 2404.

Although described in terms of a protective helmet that includes a rigidinner shell, a deformable outer shell, and an impact mitigation layer(e.g. compressible structure) therebetween, embodiments of the comfortliner system can be used with other types of helmets. For example, thecomfort liner system may be used with a traditional helmet that has arigid outer shell and larger padding inside it, where the comfort linersystem provides an improved fit to the head of a wearer. The modularcomfort liner system may also be used with other types of helmets andprotective gear, such as bicycle helmets, baseball helmets, lacrossehelmets, and other sporting equipment, as well as nonsporting equipmentlike headgear designed for construction, military, or other non-sportingpurposes.

In other embodiments, it may be desirous to supplement the modular fitpods assemblies with a comfort liner or other structure, such as theliner depicted in FIGS. 21A-21C, 22A-22B, and 23 . Such a separablecomfort liner may be particularly useful in youth sports events, whereprotective helmets are often shared between players and the comfortliner elements can easily become contaminated with sweat and/or otherbodily fluids. By providing each player with an individual comfortliner, this element can be “swapped out” by each player, with theremaining elements of the helmet rinsed and/or sprayed out for a quickcleaning. If desired, comfort liners could be provided that correspondto each size of helmet.

Front Pad System and Other Components

FIGS. 26A-26F depict various view of one exemplary embodiment of animpact pad assembly 2600, which is desirably positioned within thehelmet at a location adjacent to the forehead of the wearer. The impactpad assembly 2600 can comprise at least one curved or hemisphericalpiece of deformable foam (not shown) such as a polyurethane foam and/ormemory foam (which may alternatively comprise a plurality of foampieces, if desired), which is overlaid with a flexible, elastic and/orstretchable fabric and/or mesh fabric, and a ridge plate 2602. Theimpact pad foam may be coupled to the ridge plate 2602. Furthermore, theimpact pad may have an increased surface area that conforms to thefrontal bone of the wearer's skull. The impact pad may be mounted to theinner shell, the reflex layer, and/or the outer shell to stabilize theimpact pad within the helmet. The front comfort pad assembly maydesirably be mounted additionally with the impact pad for furthercomfort and/or impact protection. Such multi-layered design of theimpact pad and/or the front assembly pad can improve impact absorptionor dissipate forces by up to 10%. If desired, a ridge plate 2602 and/orsupport straps 415 comprising a flexible plastic and/or othermaterial(s) may be incorporated into the impact pad assembly to providea transition from the inner shell to the impact foam, as well as foradditional positional stability and/or support. In the disclosedembodiment, the foam also includes one or more openings or voids 2604formed therethrough, to desirably provide the wearer with additionalcomfort and/or allow perspiration on the wearer's skin to penetrate thefoam layer.

The protective helmet may comprise other components. Components mayinclude a visor (not shown), a facemask (not shown), a chinstrap (notshown), and/or any combination thereof.

Adjustable Jaw Pod System and/or Jaw Pod Assembly

FIGS. 27A-27C illustrate a front view and a magnified view of oneembodiment of a protective helmet system 2700 with a jaw pod assembly2702. In one embodiment, the protective helmet system 2700 may comprisea helmet 2702 and a jaw pod assembly 2704. The helmet 2700 includes anouter layer. The helmet may further comprise an optional inner layer,and impact mitigation layer that is disposed beneath the outer layerand/or any combination thereof. The helmet outer layer may comprise afront portion, a crown portion, a back portion and a jaw portion. Thejaw portion extends from the ear region of the wearer to the mandible ofthe wearer. The helmet may further comprise a fit pod layer and/or aplurality of fit pod assemblies. The plurality of fit pod assembliesand/or fit pod layer is removably connected to the helmet, or morespecifically removably coupled to an interior surface of the inner layerand/or outer layer. The helmet may further comprise a comfort liner, thecomfort liners disposed over the at least one fit pod assembly and/orfit pod layer.

FIG. 27C depicts one exemplary embodiment of an adjustable jaw fit podassembly 2704. The jaw fit pod assembly 2704, comprising a base plate2706 that can accommodate hardware for connection to a helmet jaw region(not shown), which can be bonded to an impact mitigation foam/structure2708. In various embodiments, the base plate 2706/impact mitigationstructure 2708 combination can be removed from the helmet in emergencieswhen the helmet needs to be removed without moving the head or neck ofthe player. A modular insert 2710 can be provided which fits within arecess 2712 in the impact mitigation structure 2708, with the insert2710 comprising comfort and/or impact mitigation foam. In variousembodiments, the insert 2710 may comprise a modular piece, offered inmultiple thicknesses and/or configurations, so a user could “fine tune”tune the jaw pad fit.

A protective enclosure base is also depicted, with a base plate 2706 andvarious connective mechanisms such as screws 2714 and one or more clips2716. If desired, an impact mitigation structure 2708 (including thevarious pods described herein) or similar devices may be removablycoupled to and/or within the protective enclosure base, and theprotective enclosure base may be coupled to the base plate.

In various alternative embodiments, an adjustable jaw fit pod assembly2704 may comprise a fit pod and/or a fit pod assembly (not shown), aprotective enclosure base, a base plate, and a connection mechanism. Thefit pod may be removably coupled to the within the protective enclosurebase, and the protective enclosure base may be coupled to the baseplate. The adjustable jaw fit pod assembly may be removably coupled tothe helmet. Such fit pods and/or fit pod assemblies may be custom fittedto the player's individual needs or they may be stock pods that areavailable in different thicknesses, impact protection, comfort, and/orany combination thereof.

In another embodiment, the fit pods may also have a custom shape toconform to the shape of the wearer's temple to chin region. FIGS.28A-28E depicts various views of an alternate embodiment of a jaw fitpod system 2800. In one exemplary embodiment, the improved helmet systemmay comprise a helmet, and one or more modular jaw pod systems 2800. Thejaw fit pod system 2800 can comprise a jaw fit pod assembly and a bridgefit pod assembly. The jaw pod assembly comprises a jaw connection plate2804, a face frame or base 2808, and at least one jaw fit pod 2810. Theface frame 2808 have a first surface 2812 and a second surface 2814, thefirst 2812 or second surface 2814 has a cavity, the cavity is shaped andconfigured to receive the jaw connection plate, the jaw connection plateshaped and configured to fit within the cavity 2816. The cavity having aplurality of counter depth openings 2818, the counter depth openings2818 sized and configured to receive the posts 2824 from the jawconnection plate 2804. The jaw connection plate 2804 having a firstsurface 2820 and a second surface 2822. The jaw connection plate 2804first surface 2820 is sized and configured to fit within the recess2816, and the posts 2824 aligns with the counter depth openings 2818.The jaw connection plate 2804 is coupled to the face frame 2808. Theposts 2824 extends perpendicularly away from the from the first surface2820 of the jaw connection plate 2804. The at least one jaw fit pod 2810and/or jaw fit pod assembly having at least one foam layer, the jaw fitpod 2810 and/or jaw fit pod assembly coupled to the second surface 2822of the face frame 2808 and/or first 2820 or second surface 2822 of thejaw connection plate 2804.

The bridge fit pod assembly comprises a bridge connection plate 2802, abridge frame or base 2806, and a bridge fit pod (not shown). The bridgeframe 2806 have a first surface 2826 and a second surface 2824, thefirst 2826 or second surface 2824 has a cavity 2832, the cavity 2832 isshaped and configured to receive the bridge connection plate 2802, thebridge connection plate 2802 shaped and configured to fit within thecavity 2832, the bridge fit pod and/or bridge fit pod assembly having atleast one foam layer, the bridge fit pod and/or jaw fit pod assemblycoupled to the first 2828 or second surface 2830 of the bridge frame,and or the first 2828 or second surface 2830 of the bridge connectionplate 2802.

The bridge fit pod assembly and/or the jaw fit pod assembly beingremovably coupled to the helmet as shown in FIG. 28F. The jaw fit pod ispositioned proximate to the jaw flap region of the helmet, and/or it ispositioned within the jaw flap region of the helmet. The bridge fit podassembly is positioned adjacent to the jaw fit pod assembly, where thebridge fit pod assembly extends planar with the surface of the helmettowards the back of the head or the back of the player's jaw.

The jaw connection plate 2804 and/or the bridge connection plate 2802may be manufactured from different materials. Such different materialsmay include plastic or at least one foam layer. In addition, the faceframe and/or the bridge frame may be designed to conform to a player'sfacial contours and/or may be provided in standard sizes (small, medium,large, x-large, etc.). The face frame 2808 and/or the bridge frame 2806may be manufacture d from a plastic material and/or a foam layer/foammaterial. For example, if the face frame 2808 and/or the bridge frame2806 is desirably manufactured from at least one foam layer, it may becompression or injection molded with the intended features, and/or bemanufactured from any methods know in the art.

The jaw fit pod 2810, the jaw fit pod assembly, the bridge fit pod,and/or the bridge fit pod assembly may be removably coupled to thebridge frame 2806 and/or the face frame 2808. Such removable connectionmay include Velcro, adhesive, snap posts, the connection mechanismdescribed herein), and/or any mechanical connection known in the artthat allows quick release and easy connection. This connection mechanismmay be used in conjunction with the jaw fit pod assembly and/or thebridge fit pod assembly.

Example Embodiments

1. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having at least one outer layer; a fit pod layer; thefit pod layer comprises a plurality of fit pod assemblies, each of theplurality of fit pod assemblies include a fit pod and a connectionmechanism, at least a portion of the fit pod layer removably coupled tothe helmet.

The improved helmet system of claim 1, wherein the helmet furthercomprises an inner layer.

The improved helmet system of claim 2, wherein the helmet furthercomprises an impact mitigation layer, the impact mitigation layer isdisposed between the helmet inner layer and helmet outer layer.

The improved helmet system of claim 1, wherein the improved helmetsystem further comprises at least two jaw fit pod assemblies.

The improved helmet system of claim 1, wherein the improved helmetsystem further comprises a comfort liner.

The improved helmet system of claim 1, wherein the each of the pluralityof fit pods comprises a single foam layer.

The improved helmet system of claim 1, wherein each of the plurality offit pods comprises a pocketed fit pod, the pocketed fit pod comprises atop layer, at least one foam layer, and a bottom layer, the at least onefoam layer disposed between the top layer and the bottom layer.

The improved helmet system of claim 1, wherein the plurality of fit podshaving a thickness of 0.25 inches to 1.25 inches.

The improved helmet system of claim 1, wherein the plurality of fit podsremovably coupled to the helmet in different regions, the differentregions include such as one or more of the following: a frontal assembly(or front), a crown assembly, an occipital assembly (or lower-back), amid-back assembly (right and/or left sides), a parietal assembly (ormidline), and a temporal assembly (right and/or left sides), and/or anycombination(s) thereof.

The improved helmet system of claim 1, where at least a portion of thefit pod layer are permanently coupled to the helmet.

2. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having at least one outer layer; a fit pod layer; thefit pod layer comprises a plurality of fit pod assemblies, each of theplurality of fit pod assemblies include a fit pod and a connectionmechanism, at least a portion of the fit pod layer removably coupled tothe helmet; and a comfort liner.

3. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having at least one outer layer; a fit pod layer; thefit pod layer comprises a plurality of fit pod assemblies, each of theplurality of fit pod assemblies include a fit pod and a connectionmechanism, at least a portion of the fit pod layer removably coupled tothe helmet; at least two jaw fit pod assemblies, the at least two jawfit pod assemblies removably coupled to the helmet; and a comfort liner.

4. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having at least one outer layer, at least one innerlayer, at least one impact mitigation layer, the at least one impactmitigation layer is disposed between the at least one inner layer and atleast one outer layer; a fit pod layer; the fit pod layer comprises aplurality of fit pod assemblies, each of the plurality of fit podassemblies include a fit pod and a connection mechanism, at least aportion of the fit pod layer removably coupled to the helmet; and acomfort liner.

5. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having an outer layer; a fit pod layer; the fit podlayer comprises a plurality of fit pod assemblies, each of the pluralityof fit pod assemblies include a fit pod, connection mechanism and anelastomeric support mechanism, the elastomeric support mechanism beingslidably movable from a first neutral position prior to impact, to asecond position lateral from the neutral position after impact.

The improved helmet system of claim 5, wherein the elastomeric supportsystem comprises an elastomeric structure.

The improved helmet system of claim above, wherein the elastomericstructure comprises an elastomeric polymer frame, a woven elastomericfabric or cover (such as a 2-way or 4-way stretch fabric), a fabric orcover with elastomeric properties (e.g. a woven, knit graft), one ormore spring mechanisms, and/or any combination thereof.

The improved helmet system of claim 5, wherein each of the plurality offit pods comprises a pocketed fit pod, the pocketed fit pod comprises atop layer, at least one foam layer, and a bottom layer, the at least onefoam layer disposed between the top layer and the bottom layer.

The improved helmet system of claim 5, wherein each of the plurality offit pods further comprises a low-friction surface or a low-frictionlayer.

The improved helmet system of claim 5, wherein the elastomeric supportmechanism being coupled to the connection mechanism.

The improved helmet system of claim 5, wherein the elastomeric supportmechanism being coupled to the fit pod.

6. An improved helmet system, the improved helmet system comprises: ahelmet, the helmet having an outer layer; and a impact mitigation layer;the impact mitigation layer comprises a plurality of impact mitigationstructures, each of the impact mitigation structures having connectionmechanism and an elastomeric support mechanism, the elastomeric supportmechanism being slidably movable from a first neutral position prior toimpact, to a second position lateral from the neutral position afterimpact.

The improved helmet system of claim 6, wherein the elastomeric supportsystem comprises an elastomeric structure.

The improved helmet system of claim above, wherein the elastomericstructure comprises an elastomeric polymer frame, a woven elastomericfabric or cover (such as a 2-way or 4-way stretch fabric), a fabric orcover with elastomeric properties (e.g. a woven, knit graft), one ormore spring mechanisms, and/or any combination thereof.

The improved helmet system of claim 6, wherein each of the plurality offit pods comprises a pocketed fit pod, the pocketed fit pod comprises atop layer, at least one foam layer, and a bottom layer, the at least onefoam layer disposed between the top layer and the bottom layer.

The improved helmet system of claim 6, wherein each of the plurality offit pods further comprises a low-friction surface or a low-frictionlayer.

The improved helmet system of claim 6, wherein the elastomeric supportmechanism being coupled to the connection mechanism.

The improved helmet system of claim 6, wherein the elastomeric supportmechanism being coupled to the fit pod.

The improved helmet system of claim above, wherein the elastomericpolymer frame may comprise a first portion and a second portion, thefirst portion may comprise a frame, the frame shaped and configured tomatch or substantially match the perimeter of each of the one or moreimpact mitigation structures, the second portion may comprise one ormore struts. The one or more struts having a length, the length beingallowable shear distance (or lateral distance).

The improved helmet system of claim 6, wherein the impact mitigationlayer further comprises a one or more foam layers.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The various headings and titles used herein are for the convenience ofthe reader and should not be construed to limit or constrain any of thefeatures or disclosures thereunder to a specific embodiment orembodiments. It should be understood that various exemplary embodimentscould incorporate numerous combinations of the various advantages and/orfeatures described, all manner of combinations of which are contemplatedand expressly incorporated hereunder.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention are to be construed to cover boththe singular and the plural, unless otherwise indicated herein orclearly contradicted by context. The terms “comprising,” “having,”“including,” and “containing” are to be construed as open-ended terms(i.e., meaning “including, but not limited to,”) unless otherwise noted.Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., i.e., “such as”) provided herein,is intended merely to better illuminate the invention and does not posea limitation on the scope of the invention unless otherwise claimed. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventor for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventor expects skilled artisans to employ such variations asappropriate, and the inventor intends for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1. (canceled)
 2. An impact mitigation pod assembly comprising: a fit podcomprising a top layer, a bottom layer, an outer perimeter, and at leastone foam layer disposed between the top layer and the bottom layer; anda connection mechanism comprising a first portion disposed between thetop layer of the fit pod and the bottom layer of the fit pod, and asecond portion protruding from and extending away from the bottom layerof the fit pod, the second portion configured to removably couple theconnection mechanism to a component that receives the fit pod; the toplayer of the fit pod comprising a plurality of channels formed therein,each of the plurality of channels having an end at an intersection pointof the top layer, and each of the plurality of channels extending to theouter perimeter of the fit pod.
 3. The impact mitigation pod assembly ofclaim 2, wherein the first portion of the connection mechanism has aplanar configuration.
 4. The impact mitigation pod assembly of claim 2,wherein the bottom layer of the fit pod comprises at least one openingthat is sized and configured to receive the second portion of theconnection mechanism.
 5. The impact mitigation pod assembly of claim 2,wherein the second portion of the connection mechanism is triangularshaped.
 6. The impact mitigation pod assembly of claim 2, wherein the atleast one foam layer comprises a layer of a first foam materialoverlying a layer of a second foam material.
 7. The impact mitigationpod assembly of claim 6, wherein the first foam material comprises acomfort foam and the second foam material comprises an impact foam. 8.The impact mitigation pod assembly of claim 2, wherein the bottom layerof the fit pod comprises polycarbonate.
 9. The impact mitigation podassembly of claim 2, wherein the fit pod further comprises a ventopening formed therein, extending between the top layer and the bottomlayer.
 10. The impact mitigation pod assembly of claim 9, wherein thevent opening is disposed within at least one of the plurality ofchannels.
 11. The impact mitigation pod assembly of claim 2, wherein theconnection mechanism is centrally positioned between the plurality ofchannels.
 12. An impact mitigation pod assembly comprising: a fit podcomprising: a top layer; a bottom layer; an outer perimeter; at leastone foam layer disposed between the top layer and the bottom layer; anda plurality of channels formed in the top layer, each of the pluralityof channels extending from a common intersection point of the top layerto the outer perimeter; and a connection mechanism configured toremovably couple the fit pod to a component that receives the fit pod.13. The impact mitigation pod assembly of claim 12, wherein theconnection mechanism comprises: a first portion disposed between the toplayer of the fit pod and the bottom layer of the fit pod; and a secondportion protruding from the bottom layer of the fit pod, the secondportion configured to removably secure the connection mechanism to thecomponent that receives the fit pod.
 14. The impact mitigation podassembly of claim 13, wherein the first portion of the connectionmechanism has a planar configuration.
 15. The impact mitigation podassembly of claim 13, wherein the second portion of the connectionmechanism comprises a plurality of detents.
 16. The impact mitigationpod assembly of claim 13, wherein the second portion of the connectionmechanism comprises a plurality of snap-lock tabs.
 17. The impactmitigation pod assembly of claim 12, wherein the fit pod furthercomprises at least one vent opening formed therein, extending betweenthe top layer and the bottom layer.
 18. The impact mitigation podassembly of claim 12, wherein: the fit pod further comprises at leastone vent opening disposed within each of the plurality of channels; andeach vent opening extends between the top layer and the bottom layer.19. The impact mitigation pod assembly of claim 12, wherein the at leastone foam layer comprises a comfort foam layer overlying an impact foamlayer.
 20. The impact mitigation pod assembly of claim 12, wherein eachof the plurality of channels has a channel width that is changeablebetween a first width corresponding to a planar configuration of the fitpod, and a second width corresponding to a curved configuration of thefit pod, wherein the second width is narrower than the first width.